1993-2000 Mercedes-Benz C-Class C230, C280 (W202) Service & Repair Manual

2000 ACCESSORIES/SAFETY EQUIPMENT Mercedes-Benz - Air Bag Restraint Systems DESCRIPTION & OPERATION All models are equipped with Supplemental Restraint System (SRS). The main components of SRS are driver- side air bag module, passenger-side air bag module, side air bag modules (located in doors), SRS control module, side air bag sensors, SRS warning light, driver knee bolster, passenger knee bolster, and Emergency Tensioning Retractor (ETR) seat belt assembly. Additionally, some vehicles may be equipped with head impact (curtain type) air bags (located around door windows behind door frame trims). Both SRS and ETR are electronically activated by a single control module. There are 2 thresholds which must be exceeded to trigger an ETR action, air bag deployment, or both. If a moderately severe frontal collision occurs exceeding first triggering threshold where protection from safety belt is sufficient, only Emergency Tensioning Retractor (ETR) is activated if safety belt is buckled. If a moderately severe frontal collision occurs exceeding first triggering threshold where protection from safety belt is sufficient, but safety belt is not buckled, air bag is deployed and ETR is not activated. If a severe frontal collision occurs exceeding second triggering threshold where protection from safety belt is insufficient, air bag is deployed. ETR is activated if safety belt is buckled. If safety belt is not buckled, ETR is not activated when second triggering threshold is reached. Passenger air bag will deploy even if passenger seat is not occupied when a triggering threshold is exceeded. If during a severe frontal collision the power supply is interrupted, the driver and passenger air bag can still be deployed, but ETR cannot be activated. The side air bag on the driver-side deploys whenever the driver-side air bag module is deployed and when there is a substantial side impact crash. The air bag on the passenger-side will activate only when a sensor (Occupied Seat Recognition Sensor) in the passenger seat sends a signal to the SRS control module that the passenger-side seat is occupied. During a collision, the side air bag will then deploy. COMPONENT LOCATIONS WARNING: To avoid injury from accidental air bag deployment, read and carefully follow all WARNINGS and AIR BAG SAFETY PRECAUTIONS . 1994-2000 Mercedes-Benz C230 C180 C280 C43 REPAIR MANUAL

Fig. 1: Locating Restraint System Components (E Class Shown; Others Are Similar) Courtesy of MERCEDES-BENZ SERVICING 2000 Mercedes-Benz C230 2000 ACCESSORIES/SAFETY EQUIPMENT Mercedes-Benz - Air Bag Restraint Systems

SRS AIR BAG label on driver-side door latch post indicates SRS replacement date for driver and passenger air bag units. All SRS components must be thoroughly inspected, including wiring harness. Before component replacement, check for SRS fault codes by performing system operation check. See SYSTEM OPERATION CHECK . SRS service life is 10 years from manufactured date, or 10 years from SRS replacement date after accident related repairs are completed. SYSTEM OPERATION CHECK SRS warning light indicates air bag and Emergency Tensioning Retractor (ETR) system readiness. Turn ignition on. SRS warning light will illuminate, then turn off after approximately 4-20 seconds indicating system is functioning properly. If SRS warning light does not illuminate, illuminates while driving or is continuously illuminated, there is a system fault. Repair malfunctioning system. See DIAGNOSTICS . AIR BAG SAFETY PRECAUTIONS Observe following precautions when working with air bag systems:  When working around steering column components and before any repairs are performed, disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM .  Before straightening any damage to body, or before performing electrical arc-welding, disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM .  Always wear safety glasses and gloves when handling a deployed air bag module. Air bag module may contain sodium hydroxide deposits which are irritating to the skin.  DO NOT repair any portion of SRS wiring harness.  Always handle air bag module with trim cover away from your body. Always place air bag module on workbench with trim cover up, away from loose objects.  DO NOT expose any SRS component to temperatures in excess of 212 F (100 C).  DO NOT expose any SRS component to cleaning agents such as solvents, gasoline, lye, etc.  DO NOT connect Hand-Held Tester (6511 0001 99) to Data Link Connector (DLC) with ignition on. Damage to HHT may result.  DO NOT connect HHT (6511 0001 99) to vehicle if a battery charger is connected to vehicle battery. Damage to HHT may result. ADJUSTMENTS If fixing screws were not used during clockspring removal or clockspring was rotated during removal, turn clockspring clockwise until resistance is detectable. Turn clockspring counterclockwise 2-2.5 turns until fixing screws can be unscrewed holding clockspring in this position. DISABLING & ACTIVATING AIR BAG SYSTEM DISABLING SYSTEM CAUTION: On CL500, open doors before disconnecting battery. Opening doors 2000 Mercedes-Benz C230 2000 ACCESSORIES/SAFETY EQUIPMENT Mercedes-Benz - Air Bag Restraint Systems

1. Before proceeding, follow air bag service precautions. See AIR BAG SAFETY PRECAUTIONS . Turn ignition off. On CL500, open doors to allow side windows lower. On all models, disconnect and shield negative battery cable. Remove passenger foot mat. Remove passenger footrest. Disconnect SRS system connector located at passenger footwell area. System is now disabled. ACTIVATING SYSTEM 1. Turn ignition off. Reconnect SRS system connector. Reconnect negative battery cable. System is now activated. Perform See SYSTEM OPERATION CHECK . 2. On CL500, side windows must be synchronized after battery is reconnected. To synchronize side windows, hold window switch in Close position for one second after side window is fully closed. DISPOSAL PROCEDURES Several situations may arise requiring some form of disposal action, including:  Scrapping a vehicle containing a deployed air bag module and-or ETR.  Scrapping a vehicle with a live air bag module and-or ETR.  Disposal of a live but electrically faulty air bag module and-or ETR.  Disposal of a deployed air bag module and-or ETR. DEPLOYED AIR BAG OR ETR Deployed air bag module and-or ETR unit can be thrown away. None of its components are reusable. Deployed air bag module is NOT classified as hazardous material. SCRAPPED VEHICLE 1. Before proceeding, follow service precautions. See AIR BAG SAFETY PRECAUTIONS . Move vehicle outdoors to a remote area, away from workshop and other personnel. Disconnect and shield negative battery cable. Open all vehicle windows and doors. 2. Ensure air bag module is secured to steering wheel, and passenger air bag is secured to dash. Ensure ETR allows windows to automatically lower thus preventing roof seal damage. WARNING: An undeployed air bag module or ETR should never be disposed of without first being deployed. See SCRAPPED VEHICLE . If deployment is not possible, contact vehicle manufacturer for further instructions. WARNING: An undeployed air bag module and-or ETR seat belt CANNOT be disposed of without first being deployed. If this is not possible through procedures outlined below, contact vehicle manufacturer for further instructions. Perform remote deployment outdoors. Keep personnel at least 20 feet away. 2000 Mercedes-Benz C230 2000 ACCESSORIES/SAFETY EQUIPMENT Mercedes-Benz - Air Bag Restraint Systems

seat belt assemblies are secured to "B" pillars and all seat belt buckles are latched. Remove loose objects from front seat. DO NOT allow anyone inside vehicle. 3. Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Connect Trigger Device (126-589-00-90-00) and Adapter Cable (126 589 21 63 00) to SRS system connector (X29-9) located at passenger footwell area. Move away from vehicle as far as trigger device wiring will allow. 4. To deploy driver air bag and ETR, turn rotary knob on trigger device to position No. 1. Push battery check push button and ignition push button simultaneously. Trigger light should illuminate indicating driver air bag and ETR deployed. If trigger light is illuminated and driver air bag and-or ETR did not deploy, driver air bag module and-or ETR is faulty. See UNDEPLOYED AIR BAG - ETR . 5. To deploy passenger air bag detonator No. 1, turn rotary knob on trigger device to position No. 2. Push battery check push button and ignition push button simultaneously. Trigger light should illuminate indicating passenger air bag detonator No. 1 deployed. If trigger light is illuminated and passenger air bag detonator No. 1 did not deploy, passenger air bag module is faulty. See UNDEPLOYED AIR BAG - ETR . 6. To deploy passenger air bag detonator No. 2, turn rotary knob on trigger device to position No. 3. Push battery check push button and ignition push button simultaneously. Trigger light should illuminate indicating passenger air bag detonator No. 2 deployed. If trigger light is illuminated and passenger air bag detonator No. 2 did not deploy, passenger air bag module is faulty. See UNDEPLOYED AIR BAG - ETR . UNDEPLOYED AIR BAG-ETR After deploying procedures and-or diagnostic testing have confirmed air bag module and-or ETR is undeployable, contact vehicle manufacturer for proper disposal instructions. POST-COLLISION INSPECTION See Air Bag-SRS Component Inspection & Replacement Tables in Reference Information section. REMOVAL & INSTALLATION CLOCKSPRING ASSEMBLY Removal & Installation 1. Before proceeding, See AIR BAG SAFETY PRECAUTIONS . Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . 2. Remove driver air bag module. See DRIVER - SIDE AIR BAG MODULE . Remove steering wheel bolt. Using a puller, remove steering wheel. Disconnect lower clockspring connector. Turn 2 fixing screws (locating on clockspring) counterclockwise until clockspring cannot be rotated. Remove clockspring mounting screws as necessary. Disconnect all necessary electrical connectors. Remove clockspring WARNING: Failure to follow service precautions may result in air bag deployment and personal injury. See AIR BAG SAFETY PRECAUTIONS . After component replacement, check system operation. See SYSTEM OPERATION CHECK . 2000 Mercedes-Benz C230 2000 ACCESSORIES/SAFETY EQUIPMENT Mercedes-Benz - Air Bag Restraint Systems

assembly. To install, reverse removal procedure. Activate air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Perform system operation check to ensure system is functioning properly. See SYSTEM OPERATION CHECK . CONTROL MODULE Removal & Installation Class 1. Before proceeding, See AIR BAG SAFETY PRECAUTIONS . Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Remove ignition key. Remove shift lever cover bezel. Lift shift lever cover enough to disconnect electrical connector. Remove shift lever cover. 2. Remove storage compartment mounting screws from center console. Remove storage compartment. Remove ashtray. Disconnect electrical connectors as necessary. Disconnect SRS control module electrical connector. Remove SRS control module mounting bolts. Remove SRS control module. 3. To install, reverse removal procedure. Ensure SRS control module arrow points to front of vehicle. Set parameters and program new SRS control module with Hand-Held Tester (965 589 00 01 00). Activate air bag system. Perform system operation check to ensure system is functioning properly. See SYSTEM OPERATION CHECK . Removal & Installation Class 1. Before proceeding, See AIR BAG SAFETY PRECAUTIONS . Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Remove ignition key. Remove gear shift cover panel. Remove ashtray and ashtray housing at front of console. Remove radio (if necessary). 2. Remove center console right side cover screws and right side cover. Disconnect electrical connector for control module. Remove 2 control module mounting screws. Remove control module. 3. To install, reverse removal procedure. Ensure SRS control module arrow points to front of vehicle. Set parameters and program new SRS control module with Hand-Held Tester (965 589 00 01 00). Activate air bag system. Perform system operation check to ensure system is functioning properly. See SYSTEM OPERATION CHECK . Removal & Installation Class 1. Before proceeding, See AIR BAG SAFETY PRECAUTIONS . Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Remove ignition key. Remove radio. Remove ashtray. Remove wooden surround for ashtray. Remove shift lever cover mounting screws. Push shift lever cover toward rear of vehicle and remove in an upward direction. 2. Remove center console cover screws. Remove center console cover by pulling from bottom in an upward direction. When removing covers, disconnect electrical connectors as necessary. Disconnect SRS control module electrical connector. Remove SRS control module. 3. To install, reverse removal procedure. Ensure SRS control module arrow points to front of vehicle. Set parameters and program new SRS control module with Hand-Held Tester (965 589 00 01 00). Activate air bag system. Perform system operation check to ensure system is functioning properly. See SYSTEM OPERATION CHECK . Removal & Installation Sl Class 2000 Mercedes-Benz C230 2000 ACCESSORIES/SAFETY EQUIPMENT Mercedes-Benz - Air Bag Restraint Systems

1. Before proceeding, See AIR BAG SAFETY PRECAUTIONS . Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Remove ignition key. Remove radio. Push up and pull out heater control panel. Unplug 2 connectors. Remove screw in middle of storage tray. 2. Bend up at top corners and lift out storage tray. Remove screws below storage tray. Lift wood trim panel at rear, pull down and out of catches. Unplug switch connectors and remove wood trim panel. Unplug connectors at control module and remove Torx mounting screws. Remove control module. 3. To install, reverse removal procedure. Ensure SRS control module arrow points to front of vehicle. Set parameters and program new SRS control module with Hand-Held Tester (965 589 00 01 00). Activate air bag system. Perform system operation check to ensure system is functioning properly. See SYSTEM OPERATION CHECK . Removal & Installation Clk & Slk 1. Before proceeding, See AIR BAG SAFETY PRECAUTIONS . Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Remove ignition key. Remove cover on center console. Remove cover on shift lever. Remove ash tray housing with storage compartment at front of center console. Unplug connectors at control module and remove Torx mounting screws. Remove control module. 2. To install, reverse removal procedure. Ensure SRS control module arrow points to front of vehicle. Set parameters and program new SRS control module with Hand-Held Tester (965 589 00 01 00). Activate air bag system. Perform system operation check to ensure system is functioning properly. See SYSTEM OPERATION CHECK . DRIVER-SIDE AIR BAG MODULE Removal & Installation 1. Before proceeding, See AIR BAG SAFETY PRECAUTIONS . Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Remove ignition key. Remove 2 Torx screws from rear of steering wheel. Lift off air bag module enough to unplug connector from rear of module. Place module away from work area, with pad facing upward. 2. To install, reverse removal procedure. Tighten Torx screws to specification. See TORQUE SPECIFICATIONS . Activate air bag system. Perform system operation check to ensure system is functioning properly. See SYSTEM OPERATION CHECK . SIDE AIR BAG UNIT (DRIVER-SIDE & PASSENGER-SIDE) Removal & Installation 1. Before proceeding, See AIR BAG SAFETY PRECAUTIONS . Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Remove ignition key. Drill out rivets at retaining plate of side air bag unit. Pull air bag unit out of door. Disconnect connector at driver-side air bag squib. Remove unit from vehicle. See Fig. 2 . NOTE: Air bag module and steering wheel must be replaced following a collision in which air bag was deployed. 2000 Mercedes-Benz C230 2000 ACCESSORIES/SAFETY EQUIPMENT Mercedes-Benz - Air Bag Restraint Systems

2. To install, connect connector so that connector audibly clicks when connector engages. Install unit in door trim panel and rivet using only special rivets (Part No. 003 990 0097). Perform system operation check to ensure system is functioning properly. See SYSTEM OPERATION CHECK . Fig. 2: Removing Side Air Bag Unit 2000 Mercedes-Benz C230 2000 ACCESSORIES/SAFETY EQUIPMENT Mercedes-Benz - Air Bag Restraint Systems

Courtesy of MERCEDES-BENZ SIDE AIR BAG SENSOR (DRIVER-SIDE & PASSENGER-SIDE) Removal & Installation 1. Before proceeding, See AIR BAG SAFETY PRECAUTIONS . Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Remove ignition key. On SLK 230, remove door sill moulding. On all models, remove front seat. Fold floor covering in area toward rear. Unclip connector on side bag sensor. Remove 2 mounting screws. Remove sensor from vehicle. 2. To install, reverse removal procedure. Ensure that arrow on sensor points toward outside. Perform system operation check to ensure system is functioning properly. See SYSTEM OPERATION CHECK . 2000 Mercedes-Benz C230 2000 ACCESSORIES/SAFETY EQUIPMENT Mercedes-Benz - Air Bag Restraint Systems

2000 Mercedes-Benz C230 2000 ACCESSORIES/SAFETY EQUIPMENT Mercedes-Benz - Air Bag Restraint Systems

1993-2000 Mercedes-Benz C-Class C230, C280 (W202) Service & Repair Manual

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