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Mercedes Benz 190 190E 190D Complete Workshop Service Repair Manual 1982 1983 1984 1985 1986 1987 1988 1989 1990 1991 1992 1993

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: 190 (W201) Model Variants: 190, 190E, 190D Chassis Code: W201 Codes Applicable Model Years: 1982-1993 👋 Introduction Market Position Segment: Compact Executive Sedan ('Baby Benz') Target Audience: Owners seeking to perform their own maintenance and repairs, enthusiasts, independent repair shops Competitive Analysis Competitors: BMW 3 Series (E30), Audi 80/90, Saab 900, Volvo 340/360, Alfa Romeo 75 Key Features Manual Value Proposition: Enables significant cost savings on maintenance and repairs, empowers owners with detailed knowledge, covers all aspects of vehicle service Vehicle Legacy: Established Mercedes-Benz's reputation in the compact executive segment, known for build quality, durability, and safety 📋 Manual Details Coverage Areas Overall Scope: Complete Workshop Service and Repair Engine Coverage: All petrol (E) and diesel (D) variants offered within the model years Transmission Coverage: All manual and automatic transmissions Trim And Options Coverage: All trim levels and factory options Page Count Estimated Pages: Varies by specific edition, typically extensive for full workshop manuals (often 1000+ pages) Manual Type Type: Workshop Service and Repair Manual Language Language: English Format Format: Downloadable Digital File (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, block, pistons, crankshaft, camshafts, lubrication system, cooling system Fuel System: Fuel injection (Bosch KE-Jetronic for petrol), carburetors (early models), diesel fuel injection pumps and injectors, fuel tanks, lines, pumps Engine Management: Ignition system, electronic engine control unit (ECU) diagnostics, sensor testing (crankshaft position, camshaft position, airflow meter, throttle position, lambda sensor) Transmission Manual: Clutch system, gearbox overhaul, shift mechanisms, driveshafts Transmission Automatic: Transmission overhaul, valve body, torque converter, hydraulic controls, electronic control (if applicable) Suspension: Front suspension (MacPherson struts), rear multi-link suspension, shock absorbers, springs, control arms, anti-roll bars Steering: Power steering system, steering gear, steering column, linkages Brakes: Hydraulic system, master cylinder, brake boosters, ABS (Anti-lock Braking System) diagnostics and repair, calipers, discs, drums, parking brake Electrical System: Wiring diagrams, battery, charging system (alternator, regulator), starter motor, lighting, fuses, relays, switches Body And Chassis: Body panel removal and installation, door mechanisms, locks, windows, sunroof, interior trim, structural components HVAC: Heating, ventilation, and air conditioning (HVAC) system servicing and repair, refrigerant handling, compressor, evaporator, condenser Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, tune-ups Diagnostics: Troubleshooting guides, fault code interpretation (OBD-I era), component testing Repair: Component disassembly, inspection, repair, and reassembly for all major systems Overhaul: Detailed procedures for complete engine, transmission, and other major component overhauls Specifications: Torque values, clearances, fluid capacities, electrical specifications, diagnostic parameters Technical Depth Depth: Comprehensive (from basic maintenance to full engine rebuilds and complex diagnostics) 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) Print Quality Readability: High-resolution images and clear text, optimized for printing or digital viewing Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Petrol 190E 2.3: M102.982/983 (2.3L Inline-4), 136 hp @ 5100 rpm, 205 Nm @ 3500 rpm (approx.) Primary Engine Diesel 190D 2.2: OM601.911 (2.2L Inline-4 Diesel), 73 hp @ 4400 rpm, 134 Nm @ 2800 rpm (approx.) Performance Engine Type: Inline-4 Cylinder, naturally aspirated Displacement Common: 2.0L (M102.920), 2.3L (M102.982/983), 2.2L Diesel (OM601.911), 2.5L Diesel (OM602.911) Fuel System Injection Petrol: Bosch KE-Jetronic CIS-E Fuel Injection Injection Diesel: Bosch Inline or Rotary Fuel Injection Pump 🔧 Transmission Standard Manual Option: 4-speed manual (early models), 5-speed manual (later models) Optional Automatic Option: 4-speed automatic (4G-Tronic/722.4) Features Drive Type: Rear-Wheel Drive (RWD) 📐 Dimensions Exterior Length: Approx. 4420 mm (174 in) Width: Approx. 1690 mm (66.5 in) Height: Approx. 1390 mm (54.7 in) Weights Curb Weight: Approx. 1250-1400 kg (2750-3080 lbs), varies by engine and equipment 🛡️ Safety Features Ratings Crash Test Performance: Excellent for its era; pioneered many safety features Active Features ABS: Available as an option on most models, standard on later/higher trims Passive Features Airbags: Driver's airbag became available later in the production run, optional on many models Rollover Protection: Reinforced A-pillars and body structure Seatbelts: Pre-tensioning front seatbelts on later models 💡 Technology Features Infotainment Radio: Factory-installed or dealer-installed AM/FM radio with cassette player. Options: Optional power antenna, power glass sunroof. Driver Assistance ABS: Anti-lock Braking System (optional). Cruise Control: Available as an option on most models. 🔧 Maintenance Service Intervals Oil Change Petrol: Every 10,000-15,000 km (6,000-9,000 miles) or annually, depending on driving conditions. Oil Change Diesel: Every 7,500-10,000 km (4,500-6,000 miles) or annually. Spark Plugs: Recommended replacement every 30,000-50,000 km (18,000-30,000 miles) for petrol engines, depending on plug type. Fuel Filter: Recommended replacement every 20,000-30,000 km (12,000-18,000 miles). Air Filter: Inspect every 10,000 km (6,000 miles), replace as needed (typically 20,000-30,000 km). Fluid Specifications Engine Oil Petrol: API SG or higher, SAE 10W-40 or 15W-40 (check owner's manual for climate-specific viscosity). Engine Oil Diesel: API CD or higher, SAE 15W-40 or 10W-40 (check owner's manual for climate-specific viscosity). Coolant: Mercedes-Benz approved...
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Mercedes Benz 190 190E 190D Complete Workshop Service Repair Manual 1982 1983 1984 1985 1986 1987 1988 1989 1990 1991 1992 1993
🏷️ Basic Information
Identification
Make:
Mercedes-Benz
Model:
190 (W201)
Model Variants:
190, 190E, 190D
Chassis Code:
W201
Codes
Applicable Model Years:
1982-1993
👋 Introduction
Market Position
Segment:
Compact Executive Sedan ('Baby Benz')
Target Audience:
Owners seeking to perform their own maintenance and repairs, enthusiasts, independent repair shops
Competitive Analysis
Competitors:
BMW 3 Series (E30), Audi 80/90, Saab 900, Volvo 340/360, Alfa Romeo 75
Key Features
Manual Value Proposition:
Enables significant cost savings on maintenance and repairs, empowers owners with detailed knowledge, covers all aspects of vehicle service
Vehicle Legacy:
Established Mercedes-Benz's reputation in the compact executive segment, known for build quality, durability, and safety
📋 Manual Details
Coverage Areas
Overall Scope:
Complete Workshop Service and Repair
Engine Coverage:
All petrol (E) and diesel (D) variants offered within the model years
Transmission Coverage:
All manual and automatic transmissions
Trim And Options Coverage:
All trim levels and factory options
Page Count
Estimated Pages:
Varies by specific edition, typically extensive for full workshop manuals (often 1000+ pages)
Manual Type
Type:
Workshop Service and Repair Manual
Language
Language:
English
Format
Format:
Downloadable Digital File (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, cylinder head, block, pistons, crankshaft, camshafts, lubrication system, cooling system
Fuel System:
Fuel injection (Bosch KE-Jetronic for petrol), carburetors (early models), diesel fuel injection pumps and injectors, fuel tanks, lines, pumps
Engine Management:
Ignition system, electronic engine control unit (ECU) diagnostics, sensor testing (crankshaft position, camshaft position, airflow meter, throttle position, lambda sensor)
Transmission Manual:
Clutch system, gearbox overhaul, shift mechanisms, driveshafts
Transmission Automatic:
Transmission overhaul, valve body, torque converter, hydraulic controls, electronic control (if applicable)
Suspension:
Front suspension (MacPherson struts), rear multi-link suspension, shock absorbers, springs, control arms, anti-roll bars
Steering:
Power steering system, steering gear, steering column, linkages
Brakes:
Hydraulic system, master cylinder, brake boosters, ABS (Anti-lock Braking System) diagnostics and repair, calipers, discs, drums, parking brake
Electrical System:
Wiring diagrams, battery, charging system (alternator, regulator), starter motor, lighting, fuses, relays, switches
Body And Chassis:
Body panel removal and installation, door mechanisms, locks, windows, sunroof, interior trim, structural components
HVAC:
Heating, ventilation, and air conditioning (HVAC) system servicing and repair, refrigerant handling, compressor, evaporator, condenser
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, tune-ups
Diagnostics:
Troubleshooting guides, fault code interpretation (OBD-I era), component testing
Repair:
Component disassembly, inspection, repair, and reassembly for all major systems
Overhaul:
Detailed procedures for complete engine, transmission, and other major component overhauls
Specifications:
Torque values, clearances, fluid capacities, electrical specifications, diagnostic parameters
Technical Depth
Depth:
Comprehensive (from basic maintenance to full engine rebuilds and complex diagnostics)
📊 Manual Specifications
File Format
Digital Format:
PDF (Portable Document Format)
Print Quality
Readability:
High-resolution images and clear text, optimized for printing or digital viewing
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine Petrol
190E 2.3:
M102.982/983 (2.3L Inline-4), 136 hp @ 5100 rpm, 205 Nm @ 3500 rpm (approx.)
Primary Engine Diesel
190D 2.2:
OM601.911 (2.2L Inline-4 Diesel), 73 hp @ 4400 rpm, 134 Nm @ 2800 rpm (approx.)
Performance
Engine Type:
Inline-4 Cylinder, naturally aspirated
Displacement Common:
2.0L (M102.920), 2.3L (M102.982/983), 2.2L Diesel (OM601.911), 2.5L Diesel (OM602.911)
Fuel System
Injection Petrol:
Bosch KE-Jetronic CIS-E Fuel Injection
Injection Diesel:
Bosch Inline or Rotary Fuel Injection Pump
🔧 Transmission
Standard
Manual Option:
4-speed manual (early models), 5-speed manual (later models)
Optional
Automatic Option:
4-speed automatic (4G-Tronic/722.4)
Features
Drive Type:
Rear-Wheel Drive (RWD)
📐 Dimensions
Exterior
Length:
Approx. 4420 mm (174 in)
Width:
Approx. 1690 mm (66.5 in)
Height:
Approx. 1390 mm (54.7 in)
Weights
Curb Weight:
Approx. 1250-1400 kg (2750-3080 lbs), varies by engine and equipment
🛡️ Safety Features
Ratings
Crash Test Performance:
Excellent for its era; pioneered many safety features
Active Features
ABS:
Available as an option on most models, standard on later/higher trims
Passive Features
Airbags:
Driver's airbag became available later in the production run, optional on many models
Rollover Protection:
Reinforced A-pillars and body structure
Seatbelts:
Pre-tensioning front seatbelts on later models
💡 Technology Features
Infotainment
Radio:
Factory-installed or dealer-installed AM/FM radio with cassette player.
Options:
Optional power antenna, power glass sunroof.
Driver Assistance
ABS:
Anti-lock Braking System (optional).
Cruise Control:
Available as an option on most models.
🔧 Maintenance
Service Intervals
Oil Change Petrol:
Every 10,000-15,000 km (6,000-9,000 miles) or annually, depending on driving conditions.
Oil Change Diesel:
Every 7,500-10,000 km (4,500-6,000 miles) or annually.
Spark Plugs:
Recommended replacement every 30,000-50,000 km (18,000-30,000 miles) for petrol engines, depending on plug type.
Fuel Filter:
Recommended replacement every 20,000-30,000 km (12,000-18,000 miles).
Air Filter:
Inspect every 10,000 km (6,000 miles), replace as needed (typically 20,000-30,000 km).
Fluid Specifications
Engine Oil Petrol:
API SG or higher, SAE 10W-40 or 15W-40 (check owner's manual for climate-specific viscosity).
Engine Oil Diesel:
API CD or higher, SAE 15W-40 or 10W-40 (check owner's manual for climate-specific viscosity).
Coolant:
Mercedes-Benz approved coolant concentrate (e.g., G05 or similar) mixed 50/50 with distilled water.
Transmission Fluid Auto:
Mercedes-Benz Spec 236.1 (e.g., ATF Dexron II/III compatible).
Brake Fluid:
DOT 3 or DOT 4.
Known Issues
Wiring Harness:
Degradation of insulation on engine wiring harnesses (especially for KE-Jetronic systems) leading to intermittent electrical faults.
Rust:
Susceptibility to rust in common areas such as wheel arches, rocker panels, and around window seals.
Vacuum Lines:
Cracking and deterioration of vacuum hoses leading to performance issues, idle problems, and air leaks.
Headliner:
Sagging or deteriorating headliner fabric.
Suspension Bushings:
Wear in suspension bushings (e.g., control arm bushings) causing knocking noises and poor handling.
📚 Vehicle History
Brand Heritage
Brand Legacy:
Mercedes-Benz, renowned for engineering, luxury, and durability since the early 20th century
Model Evolution
Introduction Year:
1982
Facelifts Updates:
Minor styling updates throughout its life, including chrome trim adjustments, revised bumpers, and interior enhancements.
Design Influence:
Designed by Bruno Sacco, set a new design direction for Mercedes-Benz with cleaner lines and improved aerodynamics.
Production
Production Years:
1982-1993
Production Volume:
Over 1.8 million units produced globally
Manufacturing Locations:
Mainly Sindelfingen, Germany; also assembled in various other countries.
🏆 Awards & Recognition
Recognitions
Safety Award:
Widely praised for its safety engineering and construction, setting benchmarks for its class.
Ratings
Consumer Reports:
Consistently rated well for reliability and build quality by automotive publications of its era.
Certifications
Design Award:
Credited with significantly influencing modern automotive design principles.
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