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Page 311 of 376

Mercedes-Benz C240 (2001 - 2007) Complete coverage for your vehicle Written from hands-on experience gained from the complete strip-down and rebuild of a Mercedes-Benz C240, Haynes can help you understand, care for and repair your Mercedes-Benz C240. Mercedes Benz C, CL, CLK, G, E, M, Maybach S, SL Class 1994-2013 Full Service & Repair Manual Download PDF; Mercedes Benz C,CL,CLK,G,E,M,Maybach,S & SL Class 1994-2013 Service Repair Shop Manual Download; Mercedes Benz C,CL,CLK,G,E,M,S,SL Class & Maybach Video Tutorial Body Trim Disassembly 1994-2013 Service Repair Shop Manual Download.

311 Practical hints
Towing the vehicle
Installing towing eye bolt
1Cover on right side of front bumper.2Cover on right side of rear bumper.Removing cover
0002
Press mark on cover in direction of ar-
row.
0002
Lift cover off to reveal threaded hole for
towing eye bolt.
The towing eye bolt is supplied with the
tool kit (located behind the left hand trim
panel in cargo area).
0002
Screw towing eye bolt in to its stop and
tighten with lug wrench.
Reinstalling cover
0002
Fit cover and snap into place.

Page 312 of 376

312 Practical hintsFuses
FusesFuse box in passenger compartment
1CoverOpening
0002
Pull cover1 open with a screw driver or
similar tool.
0002
Remove cover1 rearward.
Closing
0002
Attach the cover1 in the front.
0002
Fold the cover1 in until it engages.
Fuse chart
The fuse chart is found in the fuse box in
the passenger compartment. The amper-
ages of the fuses are also given there.
Fuse box in engine compartment
The fuse box is located in the engine com-
partment on the left hand side.
1Screw
2Cover
3Retainer
Removing/installing cover0002
Twist screws1 90° counterclockwise.
0002
Pull up cover2.
0002
Slide out retainer3 and remove cover
by pulling towards front.
0002
Install cover2 in reverse order.
iOnly install fuses that have been tested
and approved by Mercedes-Benz and
that have the specified amperage rat-
ing.
Never attempt to repair or bridge a
blown fuse. Have the cause determined
and remedied by an authorized
Mercedes-Benz Center.

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Kelley Blue Book

Page 313 of 376

313 Practical hintsFuses
Opening fuse box
4Fuse box cover
5Clamps0002
Release clamps5.
0002
Remove cover4.
Closing fuse box
0002
Ensure that the sealing rubber is prop-
erly positioned.
0002
Press the cover4 down and secure
with clamps5.
Auxiliary fuse box in trunk
The auxiliary fuse box is located in the
trunk.
1Trim panel
2Cover of auxiliary fuse box
3Special fuse extractor
Opening0002
Pull away trim panel1.
0002
Remove cover2.Spare fuses
Spare fuses are found in the vehicle tool kit
in the spare wheel well.

Page 314 of 376

Page 315 of 376

315 Technical data
Spare parts service
Warranty coverage
Identification labels
Layout of poly-V-belt drive
Engine
Rims and Tires
Electrical system
Main dimensions
Weights
Fuels, coolants, lubricants etc.
Consumer information

Page 316 of 376

316 Technical dataSpare parts serviceThe “Technical data” section provides the
necessary technical data for your vehicle.
Spare parts serviceAll authorized Mercedes-Benz Centers
maintain a stock of original spare parts re-
quired for maintenance and repair work. In
addition, strategically located parts distri-
bution centers provide quick and reliable
parts service.
More than 300 000 different spare parts
for Mercedes-Benz models are available.
Mercedes-Benz original spare parts are
subject to stringent quality inspections.
Each part has been specifically developed,
manufactured or selected for and adapted
to Mercedes-Benz vehicles.
Therefore, Mercedes-Benz original spare
parts should be installed.
!The use of non-genuine parts and
accessories not authorized by
Mercedes-Benz could damage the
vehicle, which is not covered by the
Mercedes-Benz Limited Warranty, or
could compromise the vehicle’s dura-
bility or safety.

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Page 317 of 376

317 Technical data
Warranty coverage
Warranty coverage
Your vehicle is covered under the terms of
the “warranties” printed in the Service and
Warranty Information booklet. Your
authorized Mercedes-Benz Center will ex-
change or repair any defective parts origi-
nally installed in the vehicle in accordance
with the terms of the following warranties:0001
New Vehicle Limited Warranty
0001
Emission System Warranty
0001
Emission Performance Warranty
0001
California, Maine, Massachusetts, and
Vermont Emission Control Systems
WarrantyReplacement parts and accessories are
covered by the Mercedes-Benz Spare Parts
and Accessories warranties, copies of
which are available at any Mercedes-Benz
Center.Loss of Service and Warranty
Information Booklet
Should you lose your Service and Warranty
Information booklet, have your authorized
Mercedes-Benz Center arrange for a re-
placement. It will be mailed to you.

Page 318 of 376

318 Technical dataIdentification labels
Identification labels1Certification label2Vehicle Identification Number (VIN)3Information label, California version
Vacuum line routing for emission con-
trol system
4Engine number (engraved on engine)
5VIN, visible (lower edge of windshield)
6Emission control label
When ordering spare parts, please specify
vehicle identification and engine numbers.

Page 319 of 376

319 Technical data
Layout of poly-V-belt drive
Layout of poly-V-belt drive
C 230 Kompressor Sport
1Power steering pump
2Idler pulley
3Mechanical loader
4Automatic belt tensioner
5Air conditioning compressor
6Crankshaft
7Coolant pump
8Generator (alternator)
C240 / C320 (all models)
1Idler pulley
2Automatic belt tensioner
3Power steering pump
4Air conditioning compressor
5Crankshaft
6Coolant pump, fan
7Generator (alternator)
C32AMG
1Idler pulley
2Idler pulley
3Supercharger
4Automatic belt tensioner
5Power steering pump
6Air conditioning compressor
7Crankshaft
8Coolant pump, fan
9Generator (alternator)

Page 320 of 376

320 Technical dataEngine
EngineModel
C 230 Kompressor Sport (203.040)
1
1The quoted data apply only to the standard vehicle. See an authorized Mercedes-Benz Center for the corresponding data of all special bodies and
special equipment.
C 240 (203.061)
1
C 240 4MATIC (203.081)
1
Engine
271
112
Mode of operation
4-stroke engine, gasoline injection
4-stroke engine, gasoline injection
No. of cylinders
4
6
Bore
3.23 in (82.00 mm)
3.54 in (89.90 mm)
Stroke
3.35 in (85.00 mm)
2.68 in (68.20 mm)
Total piston displacement
109.6 cu.in. (1 796 cm
3)
158.5cu.in. (2597cm
3)
Compression ratio
8.5:1
10.5:1
Output acc. to SAE J 1349
189 hp / 5 800 rpm
(141 kW / 5 800 rpm)
167 hp / 6 000 rpm
(125 kW / 6 000 rpm)
Maximum torque
acc. to SAE J 1349
192ft.lb/3500rpm
(260 Nm / 3 500 rpm)
177 ft.lb / 4 500 rpm
(240 Nm / 4 500 rpm)
Maximum engine speed
6000 rpm
6 200 rpm
Firing order
1-3-4-2
1-4-3-6-2-5
Poly-V-belt
7ft 11in (2420mm)
7 ft 10 in (2 390 mm)

Page 291 of 376

291 Practical hints
Replacing bulbs
Rear lamps Notes on bulb replacement
0001
Use only 12 volt bulbs of the same type
and with the specified watt rating.
0001
Switch lights off before changing a bulb
to prevent short circuits.
0001
Always use a clean lint-free cloth when
handling bulbs.
0001
Your hands should be dry and free of oil
and grease.
0001
If the newly installed bulb does not light
up, visit an authorized Mercedes-Benz
Center.
0001
Have the LEDs and bulbs for the follow-
ing lamps replaced by an authorized
Mercedes-Benz Center:0001
Additional turn signal lamps in the
exterior rear view mirrors
0001
High mounted brake lamp
0001
Xenon lamps
0001
Front fog lamps
Lamp
Type
7
High mounted brake
lamp
LED
8
Brake lamp
P21W
9
Turn signal lamp
PY 21 W
10
Backup lamp
P21W
11
Tail, parking,
standing and side
marker lamp
R5W
12
License plate lamps
C5W
13
Rear fog lamp,
driver’s side
P21W
Warning!
G
Keep bulbs out of reach of children.
Bulbs and bulb sockets can be very hot. Al-
low the lamp to cool down before changing
a bulb.
Halogen lamps contain pressurized gas.
A bulb can explode if you0001
touch or move it when hot
0001
drop the bulb
0001
scratch the bulb
Wear eye and hand protection.
Because of high voltage in Xenon lamps, it is
dangerous to replace the bulb or repair the
lamp and its components. We recommend
that you have such work done by a qualified
technician.

Page 292 of 376

292 Practical hintsReplacing bulbsReplacing bulbs for front lamps
Halogen headlamps
1Bulb socket for turn signal lamp
2Headlamp cover for high beam head-
lamp, parking and standing lamp
3Headlamp cover for low beam head-
lamp4Low beam headlamp bulb
5High beam headlamp bulb
6Bulb socket for parking and standing
lamp bulb
Low and high beam bulb
0002
Switch off the lights.
0002
Open the hood (
0003page 235).
0002
Press the clamp and remove headlamp
cover2 or 3.
0002
Pull electrical connector off.
0002
Unclip the retainer springs and take out
the bulb.
0002
Insert the new bulb so that the base
locates in the recess on the holder.
0002
Clip the retainer springs and plug the
connector onto the bulb.
0002
Align headlamp cover2 or 3 and click
into place.
Front turn signal lamp bulb
0002
Switch off the lights.
0002
Open the hood (
0003page 235).
0002
Twist bulb socket1 counterclockwise
and pull out.
0002
Push bulb into socket, turn counter-
clockwise and remove.
0002
Insert new bulb in socket, push in and
twist clockwise.
0002
Reinsert bulb socket in lamp and twist
clockwise.

Page 293 of 376

293 Practical hints
Replacing bulbs
Parking and standing lamp bulb0002
Switch off the lights.
0002
Open the hood (
0003page 235).
0002
Press the clamp and remove headlamp
cover2.
0002
Pull out the bulb socket6 with the
bulb.
0002
Pull the bulb out of the bulb socket.
0002
Insert a new bulb in the socket.
0002
Reinstall the bulb socket.
0002
Align headlamp cover2 and click into
place.Bi-Xenon* headlamps
1Bulb socket for turn signal lamp
2Headlamp cover for high beam head-
lamp, parking and standing lamp
3Headlamp cover for Bi-Xenon lamp4High beam headlamp bulb
5Bayonet socket for high beam
headlamp bulb
6Bulb socket for parking and standing
lamp bulb
High beam bulb
0002
Switch off the lights.
0002
Open the hood (
0003page 235).
0002
Press the clamp and remove headlamp
cover2.
0002
Pull electrical connector4 off.
Warning!
G
Do not remove the cover3 for the Bi-Xenon
headlamp. Because of high voltage in
Bi-Xenon lamps, it is dangerous to replace
the bulb or repair the lamp and its compo-
nents. We recommend that you have such
work done by a qualified technician.
00030003

2003 Mercedes C240 Parts

Page 294 of 376

294 Practical hintsReplacing bulbs0002
Twist bayonet socket5 counterclock-
wise to the stop (do not remove).
0002
Pull the bulb out of the socket.
0002
Insert the new bulb so that the base
locates in the recess in the bayonet
socket5.
0002
Twist bayonet socket clockwise until
you hear it snap into place.
0002
Plug the connector onto the bulb.
0002
Align headlamp cover2 and click into
place.
Front turn signal lamp bulb
0002
Switch off the lights.
0002
Open the hood (
0003page 235).
0002
Twist bulb socket1 counterclockwise
and pull out.
0002
Push bulb into socket, turn counter-
clockwise and remove.
0002
Insert new bulb in socket, push in and
twist clockwise.
0002
Reinsert bulb socket in lamp and twist
clockwise.
Parking and standing lamp bulb
0002
Switch off the lights.
0002
Open the hood (
0003page 235).
0002
Press the clamp and remove headlamp
cover2.
0002
Pull out the bulb socket6 with the
bulb.
0002
Pull the bulb out of the bulb socket.
0002
Insert a new bulb in the socket.
0002
Reinstall the bulb socket.
0002
Align headlamp cover2 and click into
place.
Side marker lamp bulb0002
Switch off the lights.
0002
Carefully slide lamp towards rear.
0002
Remove front end first.
0002
Twist bulb socket counterclockwise
and pull out.
0002
Pull bulb out of the bulb socket.
0002
Insert new bulb in socket.
0002
Reinstall bulb socket, push in and twist
clockwise.
0002
To reinstall lamp, set rear end in
bumper and let front end snap into
place.

Page 295 of 376

295 Practical hints
Replacing bulbs
Replacing bulbs for rear lamps
Tail lamp assemblies0002
Switch off lights.
0002
Open trunk lid.
1Locking lever
0002
Fold trim to the side.
0002
Turn locking lever1 to vertical position
and remove bulb carrier.2Rear fog lamp, driver’s side
3Back up lamp
4Stop lamp
5Turn signal lamp
6Tail, parking, standing and side marker
lamp
0002
Gently push bulb into socket, turn
counterclockwise and remove.
0002
Insert new bulb and turn clockwise.
0002
Reinstall bulb socket.
0002
Reinstall bulb holder and close trim
panel.License plate lamp
1Screw
0002
Switch off the lights.
0002
Loosen both screws1 and remove
lamp.
0002
Replace the tubular lamp and reinstall
lamp.
0002
Retighten the screws.

Page 296 of 376

296 Practical hintsReplacing wiper blades
Replacing wiper bladesRemoving0002
Fold wiper arm forward.
0002
Press safety tab down2.
0002
Push wiper blade downward1 and re-
move.Replacing wiper blade inserts
0002
Place wiper blade on firm support.
0002
Press down both tabs.
0002
Slide (direction of arrow) the wiper
blade insert out of the retainer claws.
0002
Slide (direction of arrow) the new wiper
blade insert into retainer claws until
tabs are engaged.
Installing0002
Slide wiper blade onto wiper arm until
it locks in place.
Warning!
G
For safety reasons, remove key from starter
switch before replacing a wiper blade, other-
wise the motor could suddenly turn on and
cause injury.
!Never open the hood when the wiper
arm is folded forward.
Do not allow the wiper arms to contact
the windshield glass without a wiper
blade inserted.
Make certain that the wiper blades are
properly installed. Improperly installed
wiper blades may cause windshield
damage.
For your convenience, we recommend
that you have this work carried out by
an authorized Mercedes-Benz Center.

Page 297 of 376

297 Practical hints
Flat tire
Flat tire
Preparing the vehicle0002
Park the vehicle as far as possible from
moving traffic on a hard surface.
0002
Turn on the hazard warning flashers.
0002
Engage the steering wheel lock in the
straight ahead position and set the
parking brake.
0002
Move the selector lever toP (manual
transmission to first or reverse gear).
0002
Have any passenger exit the vehicle at
a safe distance from the roadway.
Mounting the spare wheel0002
Prepare the vehicle as described under
'Preparing the vehicle' on this page.
0002
Take the spare wheel out of the trunk
as described on (
0003page 281) (full size
tire spare wheel) or (0003page 282)
(Minispare wheel).
Lifting the vehicle
0002
Prevent the vehicle from rolling away
by blocking wheels with wheel chocks
(not included) or other sizable objects.
When changing wheel on a level surface:
0002
Place one chock in front of and one
behind the wheel that is diagonally
opposite to the wheel being changed.
When changing wheel on a hill:
0002
Place chocks on the downhill side
blocking both wheels of the other axle.
0002
Take the two-piece wheel wrench and
the jack out of the trunk (
0003page 279).
Assemble wheel wrench.
Warning!
G
The jack is designed exclusively for jacking
up the vehicle at the jack take-up brackets
built into both sides of the vehicle. To help
avoid personal injury, use the jack only to lift
the vehicle during a wheel change. Never
get beneath the vehicle while it is supported
by the jack. Keep hands and feet away from
the area under the lifted vehicle. Always
firmly set parking brake and block wheels
before raising vehicle with jack.
Do not disengage parking brake while the
vehicle is raised. Be certain that the jack is
always vertical (plumb line) when in use, es-
pecially on hills. Always try to use the jack
on level surface. Make sure that the jack
arm is fully seated in the jack take-up
bracket. Always lower the vehicle onto suffi-
cient capacity jackstands before working
under the vehicle.
00030003

Page 298 of 376

298 Practical hintsFlat tireWheel cover on vehicles with steel rims
(Canada only)0002
O n w h e e l t o b e c h a n g e d , r e m o v e w h e e l
cover by reaching into two openings of
the wheel cover and pulling away from
the wheel.
0002
On wheel to be changed, loosen but do
not yet remove the wheel bolts
(approximately one full turn with
wrench). The jack take-up brackets are located di-
rectly behind the front wheel housings and
in front of the rear wheel housings.
0002
Place jack on firm ground.
0002
Position jack1 under the take-up
bracket2 so that it is always vertical
(plumb-line) as seen from the side,
even if the vehicle is parked on an
incline.
0002
Jack up the vehicle until the wheel is a
maximum of 1.2 in (3 cm) from the
ground. Never start engine while
vehicle is raised.

Page 299 of 376

299 Practical hints
Flat tire
Removing the wheel
1Alignment bolt0002
Unscrew upper-most wheel bolt and
remove.
0002
Replace this wheel bolt with the
alignment bolt1 supplied in the tool
kit.
0002
Remove the remaining bolts.
0002
Remove the wheel.Mounting the new wheel
1Wheel bolt for light alloy rims
2Wheel bolt for Minispare wheel or other
steel rims
0002
Clean contact surfaces of wheel and
wheel hub.
0002
Guide the spare wheel onto the
alignment bolt and push it on.
0002
Insert wheel bolts and tighten them
slightly.
!Do not place wheel bolts in sand or dirt.
This could result in damage to the bolt
and wheel hub threads.
!Wheel bolts2 must be used when
mounting steel wheel rims or the
Minispare wheel. The use of any wheel
bolts other than wheel bolts2 for steel
wheel rims or the Minispare wheel can
cause physical damage to the vehicle. !To avoid paint damage, place wheel flat
against hub and hold it there while
installing first wheel bolt.
00030003

Free 2003 Mercedes C240 Repair Manual Download Sites

Page 300 of 376

Mercedes Repair Manual Free Download

300 Practical hintsFlat tire
0002
Unscrew the alignment bolt, install last
wheel bolt and tighten slightly.Minispare wheel
Warning!
G
Always replace wheel bolts that are
damaged or rusted.
Never apply oil or grease to wheel bolts.
Damaged wheel hub threads should be
repaired immediately. Do not continue to
drive under these circumstances! Contact
an authorized Mercedes-Benz Center or call
Roadside Assistance.
Incorrect mounting bolts or improperly
tightened mounting bolts can cause the
wheel to come off. This could cause an
accident. Be sure to use the correct mount-
ing bolts.
Warning!
G
Use only genuine equipment
Mercedes-Benz wheel bolts. They are identi-
fied by the Mercedes star. Other wheel bolts
may come loose.
Do not tighten the wheel bolts when the
vehicle is raised. Otherwise the vehicle
could tip over.
Warning!
G
The dimensions of the Minispare wheel are
different from those of the road wheels. As
a result, the vehicle handling characteristics
change when driving with a Minispare wheel
mounted.
The spare wheel should only be used
temporarily, and replaced with a regular
road wheel as quick as possible.

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