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2003 MERCEDES-BENZ C240 CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT MERCEDES-BENZ REPAIR SHOPS DON'T WANT YOU TO KNOW
Learn how to repair a car or truck, install or remove parts, wire an engine, reset warning lights, replace fuel filter, fix auto body and more. Get Automotix DIY!Select Section
- Component Locations
- Wiring Diagrams
- Technical Service Bulletins
- Specifications
- A/C & Heater Service
- Brake Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator Replacement
- Cabin Air Filter Locations & Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
A/C & HEATER SERVICE PROCEDURES FOR 2003 MERCEDES-BENZ C240 AUTOMOBILES
Mercedes-Benz -> Automatic Temperature Control Systems -> Diagnosis & Testing -> 16-Pin Data Link Connector (DLC) -> 38-pin Data Link Connector (DLC) -> Accessing Diagnostic Trouble Codes -> Actual Values -> Blower Resistor -> Clearing Diagnostic Trouble Codes -> Component Diagnosis & Testing -> Diagnostic Test -> Diagnostic Trouble Code Interpretation -> Diagnostic Trouble Code Memory -> E55 AMG, E320 & E500 -> Electrical Test -> Electrical Tests -> Evaporator & Outside Temperature Sensors -> Function Tests -> Heat Exchanger & Interior Air Temperature Sensors -> Individual Flap Test -> ML55 AMG, ML350 & ML500 -> SL55 AMG, SL500 & SL600 -> Test A -> Test B -> Test C -> Using Hand-Held Tester -> Using Impulse Counter Scan Tool -> Using Temperature Display Window -> Vacuum Tests
Vehicle: 2003 MERCEDES-BENZ C240 4matic 2.6 V6 GAS
Refer to Figs. through , for explanations of symbols, connections and steps included in charts.
Accessing Diagnostic Trouble Codes
Using Impulse Counter Scan Tool
16-Pin Data Link Connector (DLC)
- Connect impulse counter scan tool No. 124-589-19-21-00, or equivalent, ground circuit 31 black wire to socket No. 1, Fig. .
- Connect ignition circuit 15 red wire to socket No. 16.
- Connect yellow wire to diagnostic output socket of system being tested, Fig. .
- LED "U-Bat" must light. If LED does not light, inspect voltage supply and...
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BRAKE SERVICE PROCEDURES FOR 2003 MERCEDES-BENZ C240 AUTOMOBILES
Anti-lock Brakes -> Description -> Components -> Electronic Control Unit -> System -> Wheel Speed Sensors
Vehicle: 2003 MERCEDES-BENZ C240 2.6 V6 GAS
System
Four-wheel ABS uses a control unit, hydraulic actuator and wheel speed sensors to control brake fluid pressure and prevent wheel lock during severe braking conditions,
Basic ABS components are supplemented by an expanded hydraulic unit, a charging pump, a fourth wheel speed sensor and a more comprehensive electronic system for Acceleration Slip Regulation (ASR) and Electronic Traction System(ETS).
Integrated with ABS and traction control systems, Electronic Stability Program (ESP) detects slides and applies brake pressure to individual wheels to help maintain control.
Components
E...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2003 MERCEDES-BENZ C240 AUTOMOBILES
Mercedes-Benz -> Fuel Filter Scheduled Maintenance -> 2003 Models w/Gasoline Engines Except E320 & E500 Sedans Less 4 Matic -> Normal Service -> Severe Service
Vehicle: 2003 MERCEDES-BENZ C240 2.6 V6 GAS
Normal Service
Repl...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 2003 MERCEDES-BENZ C240 AUTOMOBILES
DRIVESHAFT, Replace
Vehicle: 2003 MERCEDES-BENZ C240 2.6 V6 GAS
Lethal injuries are possible if vehicle slips off of lifting platform. Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer.
- Raise vehicle.
- Remove exhaust system at flange connection.
- Remove exhaust shielding plate.
- Remove bottom part of noise encapsulation.
- Remove rear engine crossmember and rear engine mount.
- Unscrew crossmember at floor shift.
- Detach front reinforcement brace below propeller shaft.
- Slacken bolts of propeller shaft intermediate bearing.
- Disconnect ...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 2003 MERCEDES-BENZ C240 AUTOMOBILES
Starter, Replace
Vehicle: 2003 MERCEDES-BENZ C240 2.6 V6 GAS
- Remove engine compartment bottom cover.
- Remove catalytic converter or front exhaust system
- Disconnect electrical con...
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CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES FOR 2003 MERCEDES-BENZ C240 AUTOMOBILES
Cabin Air Filter Service -> Mercedes-Benz -> 2002-07 C & 2002-09 CLK Class
Vehicle: 2003 MERCEDES-BENZ C240 2.6 V6 GAS
On 2002-05 models, under normal operating conditions the cabin air filter should be replaced every 15,000 miles. In dusty areas change the cabin air filter more often.
On 2006-08 models except AMG, under normal operating conditions the cabin air filter should be replaced every 24 months or 26,000 miles. In dusty areas change the cabin air filter more often.
On 2009 models except AMG, under normal operating conditions the cabin air filter should be replaced every 24 months or 20,000 miles. In dusty areas change the cabin air filter more often.
On 2006-09 AMG mo...
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MAINTENANCE LAMP RESET PROCEDURES FOR 2003 MERCEDES-BENZ C240 AUTOMOBILES
Mercedes-Benz -> Seat Belt & Backrest Lock Warning Lamp ->
Vehicle: 2003 MERCEDES-BENZ C240 2.6 V6 GAS
The Seat Belt and Backrest Lock warning lamp will illuminate when the ignition switch is placed in the On position to indicate the warning lamp is operational. After the engine has been started, the warning lamp should blink for brief time to remind driver and passenger to fasten seat belts. If the warning...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2003 MERCEDES-BENZ C240 AUTOMOBILES
Heater Hose, Replace -> Bypass -> Inlet -> Outlet
Vehicle: 2003 MERCEDES-BENZ C240 2.6 V6 GAS
Inlet
- Drain coolant into a suitable container.
- Reposition clamp on heat exchanger feed pipe and remove hose.
- Reposition clamp on thermostat housing and remove hose.
- Remove hose from vehicle.
- Reverse procedure to install.
Outlet
- Drain coolant into a suitable container.
- Reposition clamp on heat exchanger return pi...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2003 MERCEDES-BENZ C240 AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 2003 MERCEDES-BENZ C240 2.6 V6 GAS
- Open engine hood.
- Remove front engine cover.
- Remove hose from silencer.
- Remove two bolts securing charge air hose to silencer.
- Rotate or lift belt tensioner arm counterclockwise using a suita...
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COMPONENT LOCATION DIAGRAMS FOR 2003 MERCEDES-BENZ C240 AUTOMOBILES
Component location diagrams for most 2003 MERCEDES-BENZ C240 cars and light trucks sold in the U.S. from 1990+.
Exterior, Right Rear Diagram for 2003 MERCEDES-BENZ C240 4matic 2.6 V6 GAS Components on diagram: |
Right Front Door Diagram for 2003 MERCEDES-BENZ C240 2.6 V6 GAS Components on diagram: |
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WIRING DIAGRAMS FOR 2003 MERCEDES-BENZ C240 AUTOMOBILES
OEM drawn wiring diagrams for most 2003 MERCEDES-BENZ C240 cars and light trucks sold in the U.S.
2003 MERCEDES-BENZ C240 4matic 2.6 V6 GAS Wiring Diagram Components on diagram: |
2003 MERCEDES-BENZ C240 2.6 V6 GAS Wiring Diagram Components on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 2003 MERCEDES-BENZ C240 AUTOMOBILES
OEM TSB listings for most 2003 MERCEDES-BENZ C240 cars and light trucks sold in the U.S. from 1985+.
Document: Re-code the Software Calibration Number (SCN) Vehicle: 2003 MERCEDES-BENZ C240 2.6 V6 GAS Auto Systems: |
Document: Maintenance Systems Overview Vehicle: 2003 MERCEDES-BENZ C240 2.6 V6 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 2003 MERCEDES-BENZ C240 AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2003 MERCEDES-BENZ C240 cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most 2003 MERCEDES-BENZ C240 cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most 2003 MERCEDES-BENZ C240 cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most 2003 MERCEDES-BENZ C240 cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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