engine MERCEDES-BENZ C-Class 2000 W202 Service Manual

Battery

Warning !
Failure to follow these instructions can result in severe injury or death. Never lean over batteries while
connecting, you might get injured. Battery fluid contains sulfuric acid. Do not allow this fluid to come in
contact with eyes, skin or clothing. In case it does, immediately flush affected area with water and seek
medical help if necessary. A battery will also produ ce hydrogen gas, which is flammable and explosive.
Keep flames or sparks away from battery, avoid im proper connection of jumper cables, smoking etc..

Important !
Battery maintenance information:
The battery is located in the trunk under the trunk floor. The fluid level must be checked at every A and B service.
Always insure that the fluid level is at the specified maximum level and that only distilled water is used. Failure to
maintain proper fluid level may result in cell deterioration and possible battery rupture. The service life of the battery is
dependent on its condition of charge. The battery should alwa ys be kept sufficiently charged, in order to last an
optimum length of time.
Therefore, we strongly recommend that you have the battery charge checked frequently, and corrected if
necessary, especially if you use the vehicle less than approximately 200 miles (300 km) per month, mostly for
short distance trips, or if it is not used for long periods of time.
Only charge a battery with a battery charger after the battery has been disconnected from the vehicle electrical circuit.
Always disconnect the battery negative lead first and connect last. When removing and connecting the battery,
always make sure that all electrical consumers are off and the electronic key is in steering lock position 0. The battery
and its vent tube must always be securely installed when the car is in operation. While the engine is running the
battery terminal clamps must not be loosened or detached, otherwise the generator and other electronic components
would be damaged.

Note:
After reconnecting the battery also resynchronize the Express feature of the power windows, the
sliding/pop-up roof, and the Electronic Stability Program (ESP) (see Power seats, front, Head
restraints, Power windows, Sliding/pop-up roof, and Electronic stability program in Index).

Battery Recycling
Batteries contain materials that can harm the environment with improper disposal. Large 12 Volt storage batteries
contain lead. Recycling of batteries is the preferred method of disposal. Many states require sellers of batteries to
accept old batteries for recycling.

Fuses




1. Main fuse box in engine compartment

2. Auxiliary fuse box in trunk
3. Auxiliary fuse in trunk
4. Auxiliary fuse in engine compartment

Before replacing a blown fuse, determine the cause of the short circuit. Spare fuses are supplied inside the main fuse
box. Observe amperage and color of fuse. To gain access to the main fuse box (1), press clamp (arrow) , lift the fuse
box cover up and remove it. A special fuse puller comes with the vehicle tools. Always use a new fuse for
replacement. Never attempt to repair or bridge a blown fuse. After replacing a blown fuse, close fuse box cover. To
close the main fuse box, engage cover at the rear and secure with clamp.

Jump Starting

Warning !

Failure to follow these directions will cause damage to the electronic components, and can
lead to a battery explosion and severe injury or death. Never lean over batteries while
connecting or jump starting, you might get injure d. Battery fluid contains sulfuric acid. Do
not allow this fluid to come in contact with ey es, skin or clothing. In case it does, immediately
flush affected area with water, and seek medical help if necessary. A battery will also produce
hydrogen gas, which is flammable and very explosive. Keep flames or sparks away from
battery, avoid improper connection of jumper cables, smoking etc.. Read all instructions
before proceeding.

If the battery is discharged, the engine should be start ed with jumper cables and the (12 V) battery of
another vehicle.
The battery is located in the trunk under the trunk floor.

Proceed as follows:
1 . Position the vehicle with the charged battery so that the jumper cables will reach, but never
let the vehicles touch. Make sure the jump er cables do not have loose or missing insulation.
2. On both vehicles:
• Turn off engine and all lights and accessories, except hazard warning flashers or work lights.
• Apply parking brake and shift selector lever to position "P".

Important !
3. Clamp one end of the first jumper cable to the positive (+) terminal of the discharged
battery and the other end to the positive (+ ) terminal of the charged battery. Make sure
the cable clamps do not touch any other metal parts.
4. Clamp one end of the second jumper cable to the grounded negative (-) terminal of the
charged battery and the final connection to the negative (-) terminal of the discharged battery.


Important !
5. Start engine of the vehicle with the charged battery and run at high idle. Make sure the
cables are not on or near pulleys, fans, or other parts that will move when the engine is
started. Allow the discharged battery to charge for a few minutes. Start engine of the
disabled vehicle in the usual manner.
6. After the engine has started, remove jumper cables exactly reversing the above
installation sequence, starting with the last connection made first. When removing each
clamp, make sure that it does not touch any other metal while the other end is still attached.


Important !
A discharged battery can freeze at approx. +14°F (-10°C ). In that case, it must be thawed out before
jumper cables are used. A frozen battery can explode and cause personal injury.

Jumper cable specifications:
• Minimum cable cross-section of 25 mm
2 or approx. 2 AWG
• Maximum length of 11.5 ft. (3.5 m).


Note:
If engine does not run after several unsuccessful starting attempts, have it checked at the nearest
authorized Mercedes-Benz dealer. Excessive unbur ned fuel may damage the catalytic converter.

Towing the Vehicle






Warning!
Prior to towing the vehicle with all wheels on the ground, make
certain that the electronic key is in steering lock position 2.
If the electronic key is left in the steering lock position 0 for
an extended period of time, it can no longer be turned in the
lock. In this case, the steering is locked. To unlock, remove
electronic key from steering lock and reinsert.


Important !
When towing the vehicle, please, note the following:
With the automatic central locking activated and the electronic key inn steering lock position 2, the vehicle
doors lock if the left front wheel as well as the right rear wheel are turning at vehicle speeds of approx. 9 mph (15
km/h) or more. To prevent the vehicle door locks from locking, deactivate the automatic central locking.


All except C 43 AMG
The rear towing eye is located at the right, below the bumper. The front towing eye is located on the passenger side
behind a cover in the bumper panel.

Models C 230 Kompressor and C 280:
Cover removal:
Insert finger in recess on left end of cover and pull cover out.
Cover installation:
Engage cover at top right and press cover in securely.



C 43 AMG

Model C 43 AMG
Cover removal:
Hold left and right end of cover and pull out.
Cover installation:
Engage cover at bottom and press in top securely.

We recommend that the vehicle be transported using flat bed equipment. This method is preferable to other types of
towing. The vehicle may be towed with all wheels on the ground and the selector lever in position "N" for distances up
to 30 miles (50 km) and at a speed not to exceed 30 mph (50 km/h). The electronic key must be in steering lock
position 2. To positively avoid a possibility of damage to the transmission, however, we recommend to disconnect the
drive shaft at the rear axle drive flange on any towing beyond a short tow to a nearby garage. Do not tow with sling-
type equipment. Towing with sling-type equipment over bumpy roads will damage radiator and supports. Use wheel
lift, dolly, or flat bed equipment, with electronic key in steering lock turned to position 0.


Warning !
With the engine not running, there Is no power assistance for the braking and steering systems.
In this case, it is important to keep in mind that a considerably higher degree of effort is necessary
to brake and steer the vehicle.


Note:
To signal turns while being towed with hazard warning flasher in use, turn electronic key in steering lock
to position 2 and activate combination switch for left or right turn signal in usual manner - only the
selected turn signal will operate. Upon cancelling the turn signal, the hazard warning flasher will operate again.

Caution !
Vehicles with Acceleration Slip Regulation (ASR)
If the vehicle is towed with the front axle raised, the engine must be shut off (electronic key in steering lock position
0 or 1). Otherwise, the ASR will immediately be engaged and will apply the rear wheel brakes.

Caution !
Vehicles with Electronic Stability System (ESP)
If the vehicle is towed with the front axle raised, the engi ne must be shut off (electronic key in steering lock position
0 or 1). Otherwise, the ESP will immediately be engaged and will apply the rear wheel brakes.

Cleaning and Care of the Vehicle

Warning !
Many cleaning products can be hazardous. Some are poisonous, others are flammable.
Always follow the instructions on the particular container. Always open your car's doors or
windows when cleaning the inside. Never use fluids or solvents that are not designed for
cleaning your car.

In operation, your vehicle is subjected to varying external influences which, if gone unchecked, can
attack the paintwork as well as the underbody and cause lasting damage.
Such damage is caused not only by extreme and varying climatic conditions, but also by air
pollution, road salt, tar, gravel and stone chipping. Grease and oil, fuel, coolant, brake fluid, bird
droppings, insects, tree resins etc. should be removed immediately to avoid paint damage. Frequent
washing reduces and/or eliminates the aggr essiveness and potency of the above adverse
influences.
More frequent washings are necessary to deal with unfavorable conditions; for example, near the
ocean, in industrial areas (smoke, exhaust emissions), or during winter operation.
You should check your vehicle from time to time for stone chipping or other damage. Any damage
should be repaired as soon as possible to prevent the start of corrosion. In doing so, do not neglect
the underside of the car. A prerequisite for a t horough check is a washing of the underbody followed
by a thorough inspection. Damage d areas need to be reundercoated.
Your vehicle has been treated at the factory with a wax-base rustproofing in the body cavities which
will last for the lifetime of t he vehicle. Post-production treatment is neither necessary nor
recommended by Mercedes-Be nz because of the possibility of incompatibility between materials
used in the production proc ess and others applied later.
We have selected car care products and compiled recommendations which are specially matched to
our vehicles and which always reflect the late st technology. You can obtain Mercedes- Benz
approved car care products at your authorized Mercedes-Benz dealer.
Scratches, corrosive deposits, corrosion or damage due to negligent or incorrect care cannot always
be removed or repaired with the car care products recommended here. In such cases it is best to
seek aid at your authorized Mercedes-Benz dealer. The following topics deal with the cleaning and
care of your vehicle and give important "how-to" in formation as well as references to Mercedes-Benz
approved car care products. Additional information can be found in the booklet titled "Car Care".


Engine Cleaning
Prior to cleaning the engine compartment make sure to protect electrical components and
connectors from the intrusion of water and cleaning agents.
Corrosion protection, such as MB Anticorrosion Wax should be applied to the engine compartment
after every engine cleaning. Before applying, all control linkage bushings and joints should be
lubricated. The poly-V-belt and all pulleys should be protected from any wax.


Car Washing
Do not use hot water or wash your car in direct sunlight. Use only a mild car wash detergent, such
as Mercedes-Benz approved Car Shampoo.
Thoroughly spray the car with a diffused jet of wa ter. Direct only a very weak spray towards the
ventilation intake. Use plenty of water an d rinse the sponge and chamois frequently.
Rinse with clear water and thoroughly wipe dry with a chamois. Do not allow cleaning agents to dry
on the finish. If the vehicle has been run through an automatic car wash - in particular one of the
older installations - rewipe the recessed sections in the taillamps (designed to prevent soiling) if
necessary. No solvents (fuels, thi nners etc.) must be used. In the winter, thoroughly remove all
traces of road salt as soon as possible.
When washing the underbody, do not forget to clean the inner sides of the wheels.


Tar Stains
Quickly remove tar stains before they dry and beco me more difficult to remove. A tar remover is
recommended.


Window Cleaning
Use a window cleaning solution on all glass surfac es. An automotive glass cleaner is recommended.

Replacing Wiper Blade Insert

For safety reasons, remove electronic key from steering lock before replacing the wiper blade, otherwise the motor
can suddenly turn on and cause injury.

Notes:
Do not open engine hood with wiper arm folded forward. Do not allow the wiper arm to contact the windshield glass
without a wiper blade inserted. The glass may be scratched or broken. Make certain that the wiper blade is properly
installed. An improperly installed blade may cause windshield damage.

Removal:
Fold wiper arm forward. Press safety tab down (1), push wiper blade downward (2)
and remove.
Place wiper blade on firm support.
Slide (direction of arrow) the wiper blade insert out of the retainer claws.





Installation:
Slide (direction of arrow) wiper blade insert into retainer claws until tabs are engaged.
Insert wiper blade between tabs (3) on the wiper arm, and slide into end of wiper arm.
Press safety tab upward until it locks in place.


Headlamp Wiper Blades






Removal:
Fold wiper arm forward. Push pin (1) and remove wiper blade.

Installation:
Place wiper blade on wiper arm and press in pin (1).

Layout of Poly-V-belt Drive

The engine is equipped with two poly-V-belts.
For dimensions of the poly-V-belts, see Technical Data in Index.






C 230 Kompressor
Routing, Belt I


1. Crankshaft
2. Air conditioner compressor
3. Power steering pump
4. Coolant pump
5. Idler pulley


C 230 Kompressor
Routing, Belt II


6. Generator (alternator)
7. Idler pulley
8. Idler pulley
9. Supercharger


C 230 Kompressor
Routings combined, Belts I and II

Identification Labels

When ordering spare parts, please specify vehicle
identification and engine numbers.

1. Certification Label
2. Vehicle Identification No. (VIN)
3. VIN, visible (lower edge of windshield)
4. Engine No.
C 230 Kompressor, rear left,
C 280, rear right,
C 43 AMG, rear right
5. Body No. and Paintwork No.
6. Emission Control Label
7. Information Label
California version
Vacuum line routing for emission control system

Technical Data C 230 KOMPRESSOR
Model C 230 KOMMPRESSOR
(202 024)1 Rims - Tires (except Sport Package)
Engine 111 Rims (light
alloy rims)

7J x 15 H 2
Mode of operation 4-stroke engine,
gasoline injection
Wheel offset 1.46 in (37 mm)
No. of cylinders 4

All season
tires:;
Radial-ply tires
205/60R 15 91 H
Bore 3.58 in (90.90 mm) Winter tires;
Radial-ply tires
205/60 R 15 91 T M+S
Stroke 3.48 in (88.40 mm) C 230 KOMMPRESSOR - Canada only (ikl.spare wheel)
Total piston displacemen 140.8 cu.in. (2295 cm3)

Rims (steel
rims)
Wheel offset

61/2J x 15 H 2
1.46 in (37 mm)

Compression ratio 8.8:1

All
season;Radial-
ply tires
Winter
tires;Radial-ply
tires

195/65 R 15 91 H
S

Output acc. to SAE J
1349
185 hp/5300 rpm
(136 kW/5300 rpm)
Rims All season Tires ( Sport Package)
Maximum torque acc.
to SAE J 1349
200 ft.lb./2500 rpm
(270 Nm/2500rpm)

Rims (light
alloy rims)
Wheel offset

7J x 16 H 2
1.46 in (37 mm)

Maximum engine speed 5800 rpm

All season
tires:
Radial-ply tires205/55 R 16 91 H
Firing order 1-3-4-2 Electrical System
tPoly-V-belt routing I 1875 mm Generator
(alternator)

14 V/90 A
Poly-V-belt routing II 1339 mm Starter motor 12 V/1.7KW
Weights See certification tag Battery 12 V/100 Ah
Roof load max.
Trunk load max.

220 lb(100 kg)
220 lb(100 kg)

Spark plugs
Electrode gap
Tightening
torque

Bosch F 7 KTCR
0.039 in (1,0 mm)
15-22ft.lb. (20-30 Mm)

Spare Wheel Main Dimensions
Rim (light alloy rim)
Wheel offset 7 J x 16 H 2
1.46 in (37 mm) Overall vehicle
length 178.2 in (4526 mm)
All season tire:
Radial-ply tire 205/55 R 16 91 H Overall vehicle
width 67.8 in (1723mm)
Overall height 56.1 in (1424 mm)
Spare Wheel ( exept Canada model with steel rims) Wheel base 105.9 in (2690 mm)
Rim (light alloy rim)
Wheel offset 7 J x 15 H 2
1.46 in (37 mm) Track, front 59.0 in (1499 mm)
All season tire:
Radial-ply tire 205/55 R 16 91 H Track, rear 57.6 in (1464mm)

1 The quoted data apply only to the standard vehicle. See an authorized Mercedes-Benz
dealer for the correspon-ding data of ali specialbodies and special equipment,