2004 Mercedes C-Class (W203) Service and Repair Manual

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: C-Class Model Code: W203 Model Year: 2004 Codes Chassis Code: W203 Platform: W203 Platform 👋 Introduction Market Position Segment: Compact Executive Sedan/Coupe/Wagon Positioning:...

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标签: 2004 C-Class Car Cars Mercedes Mercedes-benz Misc W203

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Description

🏷️ Basic Information

Identification

Make:

Mercedes-Benz

Model:

C-Class

Model Code:

Model Year:

Codes

Chassis Code:

Platform:

W203 Platform

👋 Introduction

Market Position

Segment:

Compact Executive Sedan/Coupe/Wagon

Positioning:

Premium compact luxury vehicle offering refined comfort, advanced technology, and strong brand prestige.

Competitive Analysis

Key Competitors:

BMW 3 Series (E46), Audi A4 (B6), Lexus IS300, Infiniti G35

Key Features

Design:

Modern, flowing lines with signature Mercedes-Benz grille and interior quality.

Performance:

Responsive engines, refined handling, and comfortable ride quality.

Technology:

Introduction of advanced features like COMAND infotainment and advanced safety systems.

📋 Manual Details

Coverage Areas

Coverage:

All models and all repairs A-Z

Page Count

Estimated Page Count:

1500+

Manual Type

Type:

Factory Service and Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete overhaul, timing, lubrication, cooling, fuel delivery, emissions control

Engine Management:

ECU diagnostics, sensor data, ignition system, fuel injection control

Transmission Manual:

Clutch, gear selection, overhaul, fluid service

Transmission Automatic:

Control module diagnostics, valve body, torque converter, fluid service, overhaul

Drivetrain:

Drive shafts, CV joints, differential, axles

Suspension:

Front and rear suspension components, alignment, shock absorbers, springs, bushings

Steering:

Power steering system, steering rack, tie rods, steering column

Brakes:

ABS, ESP, brake discs, pads, calipers, lines, master cylinder, bleeding procedures

Electrical System:

Battery, alternator, starter, wiring diagrams, fuse boxes, relays

Lighting:

Headlights, taillights, interior lighting, bulb replacement, aiming

HVAC:

Air conditioning system, heater core, blower motor, climate control module, refrigerant servicing

Body Interior:

Door panels, seats, dashboard, trim, headliner, glass replacement

Body Exterior:

Bumpers, fenders, hood, trunk lid, doors, body panel alignment, rust repair

Infotainment:

Audio system, navigation, display unit, control modules

Comfort Systems:

Power windows, power locks, power mirrors, keyless entry, sunroof operation

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs

Diagnostics:

Troubleshooting guides, fault codes (DTCs), diagnostic procedures for all systems

Repair:

Step-by-step repair instructions for all major components and systems

Rebuilds:

Engine and transmission overhaul procedures, component-specific rebuilds

Adjustments:

Alignment adjustments, electronic system calibrations, clutch adjustments

Electrical Repairs:

Component replacement, wiring harness repair, circuit troubleshooting

Body Repairs:

Panel replacement, dent repair, glass installation, sealing procedures

Technical Depth

Depth:

Comprehensive; from basic maintenance to complete engine/transmission rebuilds and advanced electronic diagnostics

Detail Level:

Factory-level detail with specific torque specifications, clearances, and diagnostic procedures

Audience:

Professional technicians and advanced DIY enthusiasts

📊 Manual Specifications

File Format

File Type:

Searchability:

Fully searchable text for quick information retrieval

Print Quality:

High-resolution, printable pages for workshop use

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Quality:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Options:

M271 (1.8L Supercharged I4), M111 (2.0L Supercharged I4), M271 (2.0L Turbocharged I4), M112 (2.6L V6), M112 (3.2L V6), M113 (5.4L V8 - C32/C55 AMG)

Engine Displacements:

1.8L, 2.0L, 2.6L, 3.2L, 5.4L

Performance

Horsepower Range:

140 hp - 369 hp (depending on engine)

Torque Range:

140 lb-ft - 376 lb-ft (depending on engine)

Fuel System

Fuel Type:

Premium Unleaded Gasoline (91 RON or higher recommended)

Injection System:

Sequential Multi-Port Fuel Injection (MPI) or Direct Injection (DI) for some later variants not typically in 2004

Engine Codes Common

M271 Evo:

Commonly found 1.8L (271.940, 271.942) and 2.0L (271.860, 271.941) variants with variable valve timing and supercharging/turbocharging.

M112 V6:

Robust 2.6L (112.910) and 3.2L (112.912, 112.916) SOHC V6 engines known for smoothness.

🔧 Transmission

Standard

Transmission Options:

5-speed manual (less common), 5-speed automatic (722.6 '5G-TRONIC'), 6-speed manual (later models)

Optional

Automatic Transmission:

722.6 5-speed automatic, a highly regarded and durable transmission.

Features

Automatic Modes:

Comfort (C) and Sport (S) modes available on 722.6 transmission.

Fluid Specifications

722.6 Fluid:

MB 236.10 or MB 236.14 (ATF Dexron III/Mercon equivalent for older specs, newer specs are synthetic)

📐 Dimensions

Exterior

Length:

Approximately 4526 mm (178.2 in)

Width:

Approximately 1728 mm (68.0 in)

Height:

Approximately 1407 mm (55.4 in)

Wheelbase:

Approximately 2715 mm (106.9 in)

Weights

Curb Weight:

Approximately 1450-1600 kg (3200-3520 lbs) depending on engine and trim

Gross Vehicle Weight:

Approximately 1900-2050 kg (4189-4520 lbs) depending on configuration

🛡️ Safety Features

Ratings

NHTSA Front Impact:

5-Star (for driver and front passenger)

IIHS Frontal Offset:

Good (for early W203 models, later updates improved structure)

Euroncap Overall:

4-Star (for 2002 models, likely similar for 2004)

Active Features

Stability Control:

Standard ESP (Electronic Stability Program) on most models.

Braking System:

ABS (Anti-lock Braking System), Brake Assist (BAS)

Passive Features

Airbags:

Front airbags, side airbags, optional curtain airbags.

Seatbelts:

Pretensioners and force limiters on front seats, ISOFIX child seat anchors.

Body Structure:

High-strength steel safety cell with crumple zones.

💡 Technology Features

Infotainment

Infotainment System:

COMAND (Cockpit Management and Navigation) system available on higher trims, featuring CD player, radio, navigation, and optional phone integration.

Instrument Cluster:

Clear, multi-function display providing vehicle status, trip computer, and diagnostic information.

Driver Assistance

Cruise Control:

Standard cruise control, optional DISTRONIC adaptive cruise control on some models.

Parking Sensors:

Optional Parktronic parking assist system (front and rear).

Connectivity

Phone Integration:

Optional Bluetooth phone preparation with cradle or integrated system.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically 15,000 km (9,300 miles) or 12 months, whichever comes first, with synthetic oil. Varies with driving conditions and oil type used.

Major Service:

Major services (e.g., spark plug replacement, transmission fluid change) recommended at higher mileages, often around 60,000-100,000 km (37,000-62,000 miles) depending on specific components.

Fluid Specifications

Engine Oil:

MB 229.5 (e.g., Mobil 1 0W-40, Castrol EDGE 0W-40) is commonly recommended for gasoline engines. Always verify for specific engine. Capacity approx. 5.5-8.5L depending on engine.

Coolant:

MB 325.0 (Antifreeze/Coolant, ethylene glycol-based) or MB 326.0 (Pre-diluted) - typically a pinkish-red color. Capacity approx. 8-9L.

Brake Fluid:

DOT 4 PLUS (MB 331.0 specification)

Known Issues

M271 Timing Chain:

Potential stretching of the timing chain and wear on the tensioner and guides, leading to timing issues and noise. Early warning signs can include rattle on startup.

Oil Cooler Seals:

Leaking oil cooler seals, especially on the M112/M113 V6/V8 engines, can cause coolant contamination.

Evap Canister Purge Valve:

Faulty EVAP purge valve can lead to check engine lights and rough idling, particularly on M271 engines.

Window Regulators:

Plastic components in window regulators can degrade, leading to windows falling down inside the door.

Suspension Bushings:

Wear and tear on control arm bushings, especially front lower control arms, can cause clunks and affect alignment.

Mass Airflow Sensor Maf:

Can become dirty or fail, leading to poor engine performance and check engine lights.

📚 Vehicle History

Brand Heritage

Brand:

Mercedes-Benz: Renowned for engineering excellence, luxury, and safety innovations since the early 20th century.

Model Evolution

W203 Generation:

Second generation of the C-Class, replacing the W202. Introduced in 2000.

Facelift:

The 2004 model year typically corresponds to the pre-facelift W203 (introduced 2000-2003). A significant facelift occurred for the 2005 model year, with styling and feature updates.

Production

Production Years W203:

2000 - 2007

Manufacturing Locations:

Germany (Sindelfingen, Bremen), South Africa, Malaysia, Egypt, Thailand.

🏆 Awards & Recognition

Recognitions

General Reputation:

Consistently praised for ride comfort, build quality, and interior refinement within its segment.

Safety Awards:

Received strong safety ratings from various automotive safety organizations (as detailed in safety section).