Mercedes-Benz W203

Mercedes-Benz W203 (C-Class 2000–2007, including the S203 estate and CL203 coupe): common faults, maintenance guides and repair tips.

Mercedes-Benz W203 CDI: one side of the fuel tank does not empty (transfer pump)

The tank has two halves, and fuel is moved from one side to the other by an equalising or transfer pump. If the transfer does not work, one side stays...

C270 CDIC200 CDIS203 270 CDI

Mercedes-Benz W203 high-pressure pump leak

The most common cause is the pump's hardened O-rings in the fuel line connectors, along with the cover seals. The cover bolts can also work loose over...

200 CDI220 CDIC200 CDI270 CDI

Mercedes-Benz W203 CDI: injector return leak test and leaking injectors

The return lines are disconnected from the injectors and routed into separate containers, after which the engine is cranked or run briefly. The test i...

C200 CDIC220 CDIC270 CDI200 CDI220 CDI270 CDI

Mercedes-Benz W203 CDI: air in the fuel system

Yes. The most common cause is hardened O-rings (round sealing rings) on the ends of the fuel lines, which let air into the low-pressure side. Symptoms...

200 CDIC200 CDIC220 CDI220 CDI270 CDI

Mercedes-Benz W203 CDI starts poorly when cold

The most common causes are air getting into the fuel line and too large an injector return leak. Air gets in through hardened O-rings and connectors, ...

200 CDI220 CDI270 CDIC200 CDIC220 CDIC270 CDI

Mercedes-Benz W203 CDI: boost pressure too low and turbocharger faults

The car limits power when boost pressure deviates from the permitted range. The cause is usually the boost pressure sensor, the turbocharger actuator ...

200 CDI220 CDI270 CDI320 CDI

Mercedes-Benz W203 CDI: revs limited to about 3000 rpm

Revs limited to about 3000 is the engine's limp mode: the control unit limits power when some measurement or the boost pressure does not match. The fa...

C200 CDI

Mercedes-Benz W203 CDI stalls at full throttle and the EPC light comes on

The EPC light indicates an engine power limitation. Stalling is usually caused by the fuel pressure in the injector rail being too low. The system shu...

200 CDI220 CDI270 CDIC200 CDIC270 CDI

Mercedes-Benz W203 M271: timing chain stretch and replacement

Typical symptoms are uneven running, misfires and revs dropping. The chain can stretch or jump a tooth or more, which shifts the engine timing. Drivin...

C180 KompressorC180KC200K

Mercedes-Benz W203 misfires and rough running

Most often a faulty ignition coil, spark plugs or leads. Other causes are a leaking vacuum hose or breather hose, the fuel pump or a clogged fuel filt...

C180 KompressorC320

Mercedes-Benz W203: engine does not warm up and the thermostat

The most common cause is a faulty thermostat: if it opens too early, the temperature stays low, and if it sticks closed, the engine overheats. Normal ...

C180 KompressorC320200 CDI220 CDIC200 CDI

Mercedes-Benz W203: coolant loss

Common leak points are the water pump, the heater core, the thermostat housing, the auxiliary heater gasket and the heating coil of the windscreen was...

200 CDI270 CDI

Mercedes-Benz W203 CDI electric auxiliary heater

The auxiliary heater is on the side of the engine under the intake manifold above the starter motor, a small aluminium box with wiring. It is usually ...

200 CDI220 CDIC270 CDI

Mercedes-Benz W203 climate control flaps and temperature control

The most common cause is the plastic lever of the flap motor, which has cracked or broken. The unit interprets the flap as stuck when it does not move...

C220 CDIC270270 CDI

Mercedes-Benz W203 air conditioning not cooling

The most common causes are a refrigerant leak (for example from the condenser, the core in front of the radiator), a fault in the compressor or its el...

C180C200K

Mercedes-Benz W203 automatic transmission oil change (722.6)

The oil must be approved for the transmission, not just any ATF. The 722.6 takes oil rated MB 236.10 or 236.14, the 722.9 transmission only 236.14. Ch...

C200 CDIC240C270 CDI200 CDI220 CDI270 CDI320 CDI

Mercedes-Benz W203 automatic gear selector and fault code P1856

P1856 means the selector lever position detection is not working. The car usually stays in one gear, for example second, and the gear display is blank...

C200 CDIC270 CDI

Mercedes-Benz W203 automatic transmission conductor plate and jerking when cold

Common causes are an old conductor plate, the TCC solenoid (the valve that controls torque converter lock-up) and a leaking bushing at the bulkhead co...

200 CDI220 CDIC200 CDI270 CDI

Mercedes-Benz W203: automatic transmission limp mode and speed sensors

The cause is often the transmission conductor plate, which carries the speed sensor signals. Typical fault codes are P220A (sensor comparison not plau...

C200 CDIC220 CDIC270 CDI200 CDI220 CDI270 CDI

Mercedes-Benz W203: battery drains when parked

On a diesel the most common cause is a faulty electric auxiliary heater, located on the side of the engine under the intake manifold, which can draw a...

200 CDI220 CDI270 CDIC32S203

Mercedes-Benz W203 alternator not charging and battery warning

Measure the voltage at the battery terminals with the engine running. Normally the voltage is about 14 V. If it is about 11-12 V or does not rise afte...

200 CDI220 CDI270 CDI

Mercedes-Benz W203 ignition switch does not recognise the key

One common cause is the fibre optic inside the ignition switch, which collects dust and moisture. The dirt blocks the infrared signal, and the fault g...

C200C220 CDI200 CDI

Mercedes-Benz W203 light switch and headlight malfunctions

The cause is often the light switch connector: it is oxidised or its conductor pin has broken. Then the light functions and the side mirror adjustment...

Mercedes-Benz W203 Light sensor message and rain sensor

The message means that the connection between the light and rain sensor and the roof light module is broken. The usual cause is the module's circuit b...

C200 CDI270 CDI

Mercedes-Benz W203 ABS, ESP and BAS lights on

The lights usually come on when a sensor or the pump in the system reports an error. Common causes are worn brushes in the ABS/ESP pump motor, poor co...

C200 CDIC220 CDIC270 CDI

Mercedes-Benz W203 steering angle sensor and ESP light

The steering angle sensor has to be relearned. Start the car and turn the steering wheel from lock to lock a couple of times. If there is no fault, th...

200 CDI200 KC200K

Mercedes-Benz W203: handbrake does not hold or warning light stays on

The adjustment hatch is under the rear seat cushion. 1. Loosen the cables. 2. Adjust the shoes close through the bolt hole. 3. Tighten the cables from...

C220 CDI180 Kompressor

Mercedes-Benz W203: front end rattle and creak over bumps

The most common causes are the anti-roll bar's body bushes and the bar's connecting rods, also called drop links, which wear and loosen. Next, check t...

220 CDIS203CL203

Mercedes-Benz W203 rear end rattle and creak

The most common causes are loose lower or upper mounts and bushes of the rear shock absorber, the anti-roll bar's frame bushes and the front bushes of...

C180C200320 CDI

Mercedes-Benz W203 SRS light on

Common causes are battery or alternator undervoltage, a fault in the seat sensor mat or its wiring, a poor connector and interference on the CAN bus (...

C220 CDI

Mercedes-Benz W203 wipers and washers not working

The washer button must be pressed all the way down, otherwise the wipers just move. Other causes are a blocked pump inlet or washer nozzles, a seized ...

C200 Kompressor