Mercedes-Benz W202

Mercedes-Benz W202 (C-Class 1993–2000, including the S202 estate): common faults, maintenance guides and repair tips.

Mercedes-Benz W202 windscreen wiper mechanism faults

The most common cause is the plastic gear in the mechanism having lost its teeth, or the nut on the motor shaft linkage having come loose. If the moto...

C180C200

Mercedes-Benz W202 wipers run by themselves or intermittent wipe does not work

The most common causes are oxidised contacts in the multifunction stalk (the control lever next to the steering wheel), the multifunction relay in the...

C220

Mercedes-Benz W202 indicators and wipers do not work – multifunction relay

A common cause is the multifunction relay, which controls the indicators, wipers and rear window heating. Solder joints on its circuit board crack. Re...

C180C280220 CDI250 TDT

Mercedes-Benz W202 coolant warning light on although there is coolant

Most often the fault is in a sensor and not in the coolant level. The cause may be the expansion tank level sensor, the windscreen washer fluid sensor...

C180200 CDI220 CDI

Mercedes-Benz W202 electric fan runs constantly or does not run

The most common cause is the fan control box, whose regulator part can overheat and burn out. Replacing the control box has most often fixed the fault...

C180C200 CDI200 CDI220 CDI

Mercedes-Benz W202 does not reach normal temperature – thermostat

The most common cause is a thermostat stuck open: the temperature stays at about 50–60 degrees and does not rise. Replacing the thermostat usually nor...

C180C280200 CDI220 CDIC220 D

Mercedes-Benz W202 head gasket: symptoms and confirmation

It is a common cause. Other symptoms are running on fewer cylinders after a cold start, white smoke, grey engine oil, and oil or mayonnaise-like paste...

C180C200220 D

Mercedes-Benz W202 heater blows only hot air

The most common causes are the two solenoid valves in the engine bay, which stick in the wrong position, or a faulty climate control panel. A blown fu...

C220 DC180

Mercedes-Benz W202 heater blower whine

The causes are usually worn or dry bearings in the blower motor and worn brushes. The noise can be louder in frost and change with the speed....

C180

Mercedes-Benz W202 heater blower does not run or speed varies

The most common causes are the series resistor, worn brushes in the blower motor, an oxidised fuse or weak solder joints in the climate control panel....

C180

Mercedes-Benz W202 diesel does not start or cranks for a long time – air in the fuel line

When air gets into the fuel line, the pump does not get fuel but sucks air. Starting takes longer, especially on a car that has stood overnight. Air b...

250 TD220D220 CDI200 CDI

Mercedes-Benz W202 diesel: EPC light on and the car goes into limp mode

A common cause is the injection pump or its control electronics, for example the Lucas pump of the OM601 engine. First it is worth checking that no ai...

C220D200 CDI220 CDI

Mercedes-Benz W202 diesel glow plugs and glow light

Usually one or more glow plugs are dead, and the light tells you so. The alternatives are the glow relay or the fuse inside it; the relay is in the bl...

C220DC250 TD220 CDI200 CDI220D

Mercedes-Benz W202 BAS/ASR and ESP lights on

The most common cause is a faulty brake light switch, which gives the control unit a wrong signal. Other causes are the wheel speed sensors and their ...

C180200 CDI220 CDI

Mercedes-Benz W202 ABS light on: most common causes and measurement

Common causes are a faulty wheel sensor or its wiring (the front sensors break more easily), a fault between the sensor and the ABS ring, the YJ relay...

C180220 DC220 DC250 D200 D

Mercedes-Benz W202 battery drains when parked

Once the car has stood and its devices have gone to sleep, the standby current should be under 100 mA, typically 40–80 mA. With the alarm it can be ab...

C220 DC180

Mercedes-Benz W202 alternator not charging or wrong voltage

The most common causes are worn-out alternator brushes, a faulty voltage regulator or a broken alternator exciter wire. Sometimes the cause is also a ...

C180C220C280C250TDC200 CDI220 CDI

Mercedes-Benz W202 ignition coils and a dead cylinder

Often it is. You can check a coil by swapping the coils with each other: if the fault moves with the coil, the coil is broken. A multimeter can show a...

C180C200C220C280

Mercedes-Benz W202 mass air flow sensor (MAF) – symptoms, cleaning and replacement

Not in all versions. In the 1.8 and 2.0 litre M111 petrol engines the air quantity is estimated from the intake manifold vacuum sensor, the throttle p...

C180C200 KompressorC220220 CDI

Mercedes-Benz W202 petrol engine uneven idle

The most common causes are a dirty or faulty throttle body, the mass air flow sensor (MAF) and an intake air leak. First try cleaning the throttle bod...

C180C220C280

Mercedes-Benz W202 petrol engine won't start: fuel pump and relay

Switch the ignition on and listen for the pump hum. Make sure there is fuel in the tank and that fuel comes out of the filter's inlet pipe. If the pum...

C180C280C240C220

Mercedes-Benz W202 automatic transmission won't shift or slips

Typical causes are the conductor plate inside the gearbox and its connector, the gear selector, the speed sensor signal and too low a charging voltage...

C250 TurboC280220 CDI230 Kompressor200 Kompressor

Mercedes-Benz W202 automatic transmission oil change and oil level

A plain change of about 3.5 litres leaves about half of the old oil in the gearbox. That is why the oil change is worth doing as a flush; the flush ne...

C200C230 KompressorC250 TD

Mercedes-Benz W202 automatic gear lever stuck in P

The lever releases only when the ignition is on and the brake pedal is pressed; if the system works, you hear a click. The fault can be a faulty brake...

C180C240

Mercedes-Benz W202 manual gearbox faults

The most common cause is a missing or worn rubber bushing on the gear shift rod or the gear lever. Replace the rubber bushings and check the centring ...

C180C280200D

Mercedes-Benz W202 clutch pedal stuck down or weak

The cause is usually the clutch master or slave cylinder. If fluid runs under the mats, the fault is in the master cylinder at the pedal end. If fluid...

C180

Mercedes-Benz W202 wheel bearings – play, greasing and replacement

No play should be felt in the bearing in the vertical direction. In the horizontal direction a small amount of play may be felt when cold. The front a...

C180

Mercedes-Benz W202 lower control arms and lower ball joints

The replacement interval is roughly 180–200 thousand km. The joints usually wear at the same time, so it is not worth replacing one joint alone. Check...

250 TDTC250 TDTS202

Mercedes-Benz W202 rear tyre wear and rear alignment angles

The causes can be worn outer joints of the lower control arm, the adjusting rods or the front rubbers of the rear subframe. They are replaced when the...

220DC280C200 CDI

Mercedes-Benz W202 air conditioning not cooling – compressor and leaks

The most common cause is a refrigerant leak. Typical leak points are the compressor shaft seal, the front core of the condenser, the pressure pipe mou...

S202250 TDT

Mercedes-Benz W202 handbrake adjustment and faults

1. Loosen the automatic adjuster under the rear seat with a hex key. 2. Adjust the shoes through the wheel bolt hole close to the drum or disc. 3. Tig...

C180S202