2003 MERCEDES C-Class W203 Service and Repair Manual
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W203
MERCEDES
SERVICE
AND REPAIR
MANUAL
2001-2006 HVAC
Air Compressor, Belt Drives - 203 Chassis
TESTING & REPAIR
REMOVE/INSTALL POLY-V-BELT FOR COMPRESSOR - AR13.21-P-1202A
ENGINE 111.943 /973 in MODEL 170
ENGINE 111.944 /975 in MODEL 202, 208
ENGINE 111.947 in MODEL 210
ENGINE 111.955 in MODEL 203
Fig. 1: Identifying Poly - V - Belt For Compressor Remove/Install Components - Engine 111.955
Removing
1 Remove viscous fan
clutch (26)
Vehicles fitted with viscous
fan clutch
Left-hand thread
AR20.40-P-5660A
2.1 Remove fan shroud Vehicles with fan cowl AR20.40-P-6800HA
2.2 Remove electric fan Vehicles fitted with electric
fan
AR20.40 - P - 5000PR
3 Loosen poly-V-belt (10)
Swivel tensioning arm
(2) and tensioning pulley
(3) in counterclockwise
Fig. 2
2007 Mercedes-Benz C230
2001-2006 HVAC Air Compressor, Belt Drives - 203 Chassis
MULTI-BELT DRIVE
direction at stud bolt (4,
external Torx E10) for this
step.
Do not swivel tensioning
arm (2) against tensioning
pulley the nut.
4 Remove poly-V-belt
(10)
Checking
5 Inspect belt pulley
sections and tensioning
device for damage and
dirt.
6 Check poly-V-belt (10)
Check poly-V-belt in
visible area for wear
AP13.22-P-1352Z
Install
7 Fit on poly-V-belt (10),
then clamp
Do not use belt wax or
any similar products.
In numerical order of
relevant running diagram,
beginning at tensioning
pulley ?
Routing diagram of poly-V-
belt
AR13.21 - P - 3902 - 02A
Poly-V-belt dimensions *BE13.21-P-1001-01A
The position
marking (B) visible from
the underside of the engine,
must be positioned within
the working range (A). If
this is not the case, inspect
length of poly-V-belt and
also tensioning device
Fig. 2
8.1 Install fan shroud Vehicles with fan cowl AR20.40-P-6800HA
8.2 Install electric fan Vehicles fitted with electric
fan
AR20.40 - P - 5000PR
9 Install viscous fan clutch
(26)
Vehicles fitted with viscous
fan clutch
Left-hand thread
AR20.40-P-5660A
Number Designation Engine Engine Engine
2007 Mercedes-Benz C230
2001-2006 HVAC Air Compressor, Belt Drives - 203 Chassis
MULTI-BELT DRIVE
Fig. 2: Identifying External Torx Set (001 589 76 09 00)
REMOVE, INSTALL POLY-V-BELT FOR COMPRESSOR - AR13.21-P-1202PK
ENGINE 111.955 in MODEL 203.045 /245 /745
111.943/944/947/973/975
without AC compressor
with power steering pump
111.944/947/975
without AC
compressor with
tandem pump
111.943/944/947
973/975 with AC
compressor with
power steering
pump
BE13.21-
P-1001-
01A
Length of
belt of
compressor
drive
mm 1330 1330 1330
Number Designation Engine 111.944/947/975
with AC compressor
with tandem pump
Engine 111.955
with AC
compressor with
power steering
pump
BE13.21-P-1001-
01A
Length of belt on
compressor drive
mm 1330 1355
2007 Mercedes-Benz C230
2001-2006 HVAC Air Compressor, Belt Drives - 203 Chassis
Fig. 3: Identifying Poly - V - Belt For Compressor Remove/Install Components - Engine 111.955 In Model
203.045 /245 /745
Remove
1 Remove air filter housing
AR09.10 - P -
1150PK
2 Loosen poly-V-belt (1) and remove
Swivel stud bolt (2) at tensioning
pulley (3) in anti-clockwise direction
(arrow) for this step.
Checking
3
Inspect belt pulley sections and
tensioning device for damage and dirt,
replace if necessary
4
Inspect poly V-belt (1), replace if
necessary
Check poly-V-belt in visible area for
wear
AP13.22-P-
1352Z
Install
5 Fit on poly V-belt (1), tension
Installation: Do not use any belt wax or
similar products
Fit on poly V-belt as specified in
running diagram ?
Running diagram of poly V-belt.
AR13.22 - P -
3902 - 02PR
6 Install air filter housing
Installation: Lightly coat rubber
retainer with antifriction agent.
AR09.10 - P -
1150PK
2007 Mercedes-Benz C230
2001-2006 HVAC Air Compressor, Belt Drives - 203 Chassis
REMOVE/INSTALL POLY-V-BELT GUIDE PULLEY - AR13.21-P-3350QB
ENGINE 272.920 in MODELS 203.052 /252 /752
ENGINE 272.940 in MODELS 203.054 /254, 209.354 /454
ENGINE 272.960 in MODELS 203.056 /256 /756, 209.356 /456
ENGINE 272.970 in MODELS 203.087 /287
ENGINE 272.941 in MODELS 203.092 /292
ENGINE 273 in MODEL 209
Fig. 4: Identifying Poly - V - Belt Guide Pulley Remove/Install Components
Remove/install
Risk of injury caused by fingers being pinched or
crushed when removing, installing or aligning hoods,
doors, trunk lids, tailgates or sliding roof.
Keep body parts and limbs
well clear of moving parts.
AS00.00 - Z -
0011 - 01A
Notes on self-locking nuts and bolts
AH00.00 - N -
0001 - 01A
1 Open engine hood and raise to vertical position Model 203
AR88.40 - P -
1000P
Model 209
AR88.40-P-
1000Q
Pull front engine
2007 Mercedes-Benz C230
2001-2006 HVAC Air Compressor, Belt Drives - 203 Chassis
COOLANT PUMP, COOLANT THERMOSTAT
POLY V-BELT RUNNING DIAGRAM, MULTI-BELT DRIVE - AR13.21-P-3902-02A
Running diagram of basic drive (6-groove)
Fig. 5: Running Diagram Of Basic Drive (6 - Groove)
Running diagram of compressor drive (6-groove)
Fig. 6: Running Diagram Of Compressor Drive (6 - Groove)
REMOVE/INSTALL POLY V-BELT - AR13.22-P-1202A
ENGINE 111
2 Remove front engine cover
cover upward and out of
mountings.
3 Remove poly-V-belt
AR13.22 - P -
1202QB
4 Lever off covers (1b, 2b)
5 Remove bolts (1a, 2a)
*BA20.10 - P -
1004 - 01U
6 Remove guide pulleys (1, 2)
7 Install in the reverse order
Number Designation Engine 272 Engine 273
BA20.10-P-1004-01U Bolt, poly-V-belt guide pulley at coolant pump Nm 35 35
2007 Mercedes-Benz C230
2001-2006 HVAC Air Compressor, Belt Drives - 203 Chassis
Fig. 7: Identifying Poly V - Belt Remove/Install Components (Engine 111)
Removing
1.1 Remove viscous fan
clutch (26)
Engines with viscous fan clutch
0046 Left-hand thread
AR20.40-P-5660A
1.2 Remove electric fan Engines fitted with electric fan AR20.40 - P - 5000PR
2 Remove poly V-belt
of compressor (10)
Engine 111 with compressor AR13.21 - P - 1202A
3 Loosen poly-V-belt
(11)
Swivel tensioning arm (2) and
tensioning pulley (3) in counter-
clockwise direction at stud bolt (4,
external torx E10) for this step.
Do not swivel tensioning arm (2)
against the nut attaching the
tensioning pulley.
Fig. 2
4 Take off poly V-belt
(11)
Checking
5 Inspect belt pulley
sections and
tensioning device for
damage and dirt.
6 Inspect poly V-belt
(11)
Check poly-V-belt in
visible area for wear
Except engine 111.977 AP13.22-P-1352Z
Engine 111.977 AP13.22-P-1351GH
Install
2007 Mercedes-Benz C230
2001-2006 HVAC Air Compressor, Belt Drives - 203 Chassis
MULTI-BELT DRIVE
MULTI-BELT DRIVE
7 Fit on poly-V-belt
(11), then clamp
Do not use belt wax or similar
products.
In numerical order of relevant
running diagram, beginning at
tensioning pulley ?
Running diagram of poly V-belt of
engines not fitted with compressor
AR13.22 - P - 3902 -
02A
Running diagram of poly V-belt of
engines fitted with compressor
AR13.21 - P - 3902 -
02A
Poly V-belt dimensions of engines
not fitted with compressor
*BE13.22 - P - 1001 -
01B
Poly V-belt dimensions of engines
fitted with compressor
*BE13.21 - P - 1002 -
01A
The position marking (B)
must be positioned within the
working range (A). If this is not the
case, inspect the length of the poly
V-belt and also the tensioning device
Fig. 2
8 Install poly V-belt of
compressor
Engine 111.943/944/947/973/975 AR13.21 - P - 1202A
9.1 Install viscous fan
clutch (26)
Engines with viscous fan clutch
Left-hand thread
AR20.40-P-5660A
9.2 Install electric fan Engines fitted with electric fan AR20.40 - P - 5000PR
Number Designation Engine
111.943/944/947/973/975
without AC compressor
with power steering
pump
Engine
111.943/944/947/973/975
with AC compressor
with power steering
pump
Engine
111.944/944/947
without AC
compressor
with tandem
pump
BE13.21-
P-1002-
01A
Length of
belt of
base drive
mm 1775 1875 1760
Number Designation Engine
111.944/947/975 with
AC compressor with
tandem pump
Engine 111.955
with AC
compressor and
with power
steering pump
Engine
111.958/983
BE13.21-P-
1002-01A
Length of belt
of base drive
mm 1860 1860 1870
2007 Mercedes-Benz C230
2001-2006 HVAC Air Compressor, Belt Drives - 203 Chassis
SINGLE-BELT DRIVE
Fig. 8: Identifying External Torx Set (001 589 76 09 00)
REMOVE/INSTALL POLY V-BELT - AR13.22-P-1202PK
ENGINE 111.955 in MODEL 203.045 /245 /745
Fig. 9: Identifying Poly V - Belt Remove/Install Components - Engine 111.955 In Model 203.045 /245 /745
Number Designation Engine 111
except
111.944/947/975
without AC
compressor
Engine 111
except
111.944/947/975
with AC
compressor
Engine 111 except
111.943/944/947/973/975
without AC compressor
with VDA power
steering pump
Engine 111 except
111.943/944/947/973/975
with AC compressor
with VDA power
steering pump
BE13.22-
P-1001-
01B
Belt
length
mm 2040 2140 2055 2155
Remove
AR13.21-P-
2007 Mercedes-Benz C230
2001-2006 HVAC Air Compressor, Belt Drives - 203 Chassis
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Lifetime Access
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Online & Offline Access
Access PDF Contents & Bookmarks
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Print one or all pages of your manual
$37.99
The 2003 MERCEDES C-Class W203 Service and Repair Manual is a comprehensive guide designed to assist owners in maintaining and repairing their Mercedes-Benz C-Class W203 model from the year 2003. It is suitable for both professional mechanics and DIY enthusiasts, providing step-by-step instructions, detailed diagrams, and illustrations for various service and repair tasks.
From routine maintenance tasks such as oil changes, brake replacement, and filter replacements to more complex repairs like engine and transmission overhauls, this manual covers a wide range of procedures, ensuring the longevity and optimal performance of the vehicle.
Key features of the manual include:
- Comprehensive coverage of all major systems and components
- Easy-to-follow instructions with detailed illustrations
- Troubleshooting tips and common problem solutions
- Wiring diagrams and electrical system information
- Recommended service intervals and maintenance schedules
- Specifications and tightening torque values for various components
Whether you aim to save money on costly repairs or gain a thorough understanding of your vehicle, the 2003 MERCEDES C-Class W203 Service and Repair Manual is an essential tool for any Mercedes-Benz C-Class W203 owner. It empowers you to confidently tackle any service or repair task, ensuring your Mercedes-Benz runs smoothly for years to come.
