Mercedes Benz 190 190E 190D 1982-1993 Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: Mercedes-Benz Model: 190 / 190E / 190D Chassis Codes: W201 Model Years Covered: 1982-1993 👋 Introduction Market Position Vehicle Segment: Compact Executive Sedan Brand Perception: Represents Mercedes-Benz's entry into the compact luxury segment, aiming to compete with models like the BMW 3 Series. Competitive Analysis Key Competitors: BMW 3 Series (E30), Audi 80/90, Volvo 240, Alfa Romeo 75 Key Features Design Philosophy: Modern, functional design with a focus on safety, build quality, and driving dynamics, a departure from some of Mercedes-Benz's more traditional styling. Manual Utility: Essential for owners and independent mechanics seeking to maintain and repair the W201 chassis without relying solely on dealership services. 📋 Manual Details Coverage Areas Primary Coverage: North America, Europe Regional Variants: Includes specifications relevant to common global configurations Page Count Estimated Page Count: Hundreds (specific number not provided, but described as extensive) Manual Type Manual Type: Factory Service Repair Workshop Manual Language Language: English (implied by product description and target market) Format Digital Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine mechanicals, fuel system, ignition system, cooling system, exhaust system, transmission (manual and automatic) Chassis: Suspension (front and rear), steering system, braking system (including ABS where applicable) Electrical: Complete electrical system diagrams, starting and charging system, lighting, instruments, body electrical, comfort systems Body And Interior: Body structure, panels, doors, windows, seats, trim, HVAC system Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, lubrication Repair: Detailed step-by-step repair instructions for all major components and systems Troubleshooting: Diagnostic procedures, fault finding, symptom-based troubleshooting guides Specifications: Torque values, clearances, tolerances, diagnostic data Technical Depth Depth Of Information: Comprehensive, covering routine maintenance to complete engine and transmission rebuilds, including electrical system diagnostics and component replacement. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable PDF, enabling quick information retrieval Print Quality Print Capability: Printable (single pages or entire manual) Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Licensing Usage License: Lifetime use on unlimited devices, no expiry dates Compatibility Operating Systems: Windows and MAC compatible ⚙️ Engine Specifications Primary Engine 190E Engine Type: Inline-4 Cylinder, SOHC (M102 family) Displacement 190E 2.3: 2.3 Liters (2299 cc) Power 190E 2.3: Approx. 130-137 hp (DIN) Torque 190E 2.3: Approx. 192 Nm (DIN) Primary Engine 190D Engine Type: Inline-4 Cylinder Diesel, SOHC (OM601 family) Displacement 190D 2.0: 2.0 Liters (1997 cc) Power 190D 2.0: Approx. 72-75 hp (DIN) Torque 190D 2.0: Approx. 123 Nm (DIN) Fuel System Fuel Injection 190E: Bosch K-Jetronic (CIS) or KE-Jetronic (CIS-E) mechanical fuel injection Fuel Injection 190D: Indirect Injection (IDI) Diesel with Bosch inline injection pump 🔧 Transmission Standard Transmission Type Gasoline: 4-speed Manual (later models may offer 5-speed) Type Diesel: 4-speed Manual Optional Transmission Type Gasoline Diesel: 4-speed Automatic (722.4, later 722.5 5-speed) Features Automatic Features: Lock-up torque converter for improved efficiency 📐 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: 1200-1300 kg (2645-2866 lbs) depending on engine and equipment 🛡️ Safety Features Ratings Era Safety Focus: Designed with advanced safety features for its time, including a robust body structure and crumple zones. Active Features ABS Availability: Optional Anti-lock Braking System (ABS) on many models Passive Features Airbag Availability: Driver-side airbag became available later in the production run (optional on most, standard on some later models). Seatbelts: Pre-tensioner seatbelts available 💡 Technology Features Infotainment Radio Options: Factory radio and cassette player options available, often with basic tuning and volume controls. Driver Assistance Cruise Control: Optional cruise control system available on many models. Air Conditioning: Optional manual or automatic climate control systems. 🔧 Maintenance Service Intervals Oil Change Interval Petrol: Typically every 10,000-15,000 km (6,000-9,000 miles) or 12 months, depending on oil type and driving conditions. Oil Change Interval Diesel: Typically every 7,500-10,000 km (4,500-6,000 miles) or 12 months. Air Filter Replacement: Inspect every 20,000 km (12,000 miles), replace as needed or every 40,000 km (24,000 miles). Spark Plug Replacement: Every 40,000-60,000 km (24,000-36,000 miles) depending on plug type. Fluid Specifications Engine Oil Petrol: API SF/SG or higher, SAE 10W-40 or 15W-40 recommended (check specific viscosity for climate). Engine Oil Diesel: API CD/CE or higher, SAE 15W-40 recommended. Coolant: Mercedes-Benz Specification 325.0 (Glysantin G48 or equivalent concentrate mixed 50/50 with distilled water). Brake Fluid: DOT 3 or DOT 4 Transmission Fluid Auto: MB 236.1 specification (e.g., Dexron II or III compatible) Known Issues Cooling System: Water pump leaks, radiator deterioration, thermostat failure, head gasket issues (especially with high mileage or poor maintenance). Electrical System: Wiring harness degradation (particularly under-dash loom), vacuum line leaks, instrument cluster issues, headlamp switch failures. Fuel System Petrol: K-Jetronic system component wear (e.g., airflow meter, fuel distributor), vacuum leaks affecting mixture. Suspension: Wear in ball joints, tie rod ends, control...
Represents Mercedes-Benz's entry into the compact luxury segment, aiming to compete with models like the BMW 3 Series.
Competitive Analysis
Key Competitors:
BMW 3 Series (E30), Audi 80/90, Volvo 240, Alfa Romeo 75
Key Features
Design Philosophy:
Modern, functional design with a focus on safety, build quality, and driving dynamics, a departure from some of Mercedes-Benz's more traditional styling.
Manual Utility:
Essential for owners and independent mechanics seeking to maintain and repair the W201 chassis without relying solely on dealership services.
📋 Manual Details
Coverage Areas
Primary Coverage:
North America, Europe
Regional Variants:
Includes specifications relevant to common global configurations
Page Count
Estimated Page Count:
Hundreds (specific number not provided, but described as extensive)
Manual Type
Manual Type:
Factory Service Repair Workshop Manual
Language
Language:
English (implied by product description and target market)
Torque values, clearances, tolerances, diagnostic data
Technical Depth
Depth Of Information:
Comprehensive, covering routine maintenance to complete engine and transmission rebuilds, including electrical system diagnostics and component replacement.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable PDF, enabling quick information retrieval
Print Quality
Print Capability:
Printable (single pages or entire manual)
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Licensing
Usage License:
Lifetime use on unlimited devices, no expiry dates
Compatibility
Operating Systems:
Windows and MAC compatible
⚙️ Engine Specifications
Primary Engine 190E
Engine Type:
Inline-4 Cylinder, SOHC (M102 family)
Displacement 190E 2.3:
2.3 Liters (2299 cc)
Power 190E 2.3:
Approx. 130-137 hp (DIN)
Torque 190E 2.3:
Approx. 192 Nm (DIN)
Primary Engine 190D
Engine Type:
Inline-4 Cylinder Diesel, SOHC (OM601 family)
Displacement 190D 2.0:
2.0 Liters (1997 cc)
Power 190D 2.0:
Approx. 72-75 hp (DIN)
Torque 190D 2.0:
Approx. 123 Nm (DIN)
Fuel System
Fuel Injection 190E:
Bosch K-Jetronic (CIS) or KE-Jetronic (CIS-E) mechanical fuel injection
Fuel Injection 190D:
Indirect Injection (IDI) Diesel with Bosch inline injection pump
🔧 Transmission
Standard Transmission
Type Gasoline:
4-speed Manual (later models may offer 5-speed)
Type Diesel:
4-speed Manual
Optional Transmission
Type Gasoline Diesel:
4-speed Automatic (722.4, later 722.5 5-speed)
Features
Automatic Features:
Lock-up torque converter for improved efficiency
📐 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:
1200-1300 kg (2645-2866 lbs) depending on engine and equipment
🛡️ Safety Features
Ratings
Era Safety Focus:
Designed with advanced safety features for its time, including a robust body structure and crumple zones.
Active Features
ABS Availability:
Optional Anti-lock Braking System (ABS) on many models
Passive Features
Airbag Availability:
Driver-side airbag became available later in the production run (optional on most, standard on some later models).
Seatbelts:
Pre-tensioner seatbelts available
💡 Technology Features
Infotainment
Radio Options:
Factory radio and cassette player options available, often with basic tuning and volume controls.
Driver Assistance
Cruise Control:
Optional cruise control system available on many models.
Air Conditioning:
Optional manual or automatic climate control systems.
🔧 Maintenance
Service Intervals
Oil Change Interval Petrol:
Typically every 10,000-15,000 km (6,000-9,000 miles) or 12 months, depending on oil type and driving conditions.
Oil Change Interval Diesel:
Typically every 7,500-10,000 km (4,500-6,000 miles) or 12 months.
Air Filter Replacement:
Inspect every 20,000 km (12,000 miles), replace as needed or every 40,000 km (24,000 miles).
Spark Plug Replacement:
Every 40,000-60,000 km (24,000-36,000 miles) depending on plug type.
Fluid Specifications
Engine Oil Petrol:
API SF/SG or higher, SAE 10W-40 or 15W-40 recommended (check specific viscosity for climate).
Engine Oil Diesel:
API CD/CE or higher, SAE 15W-40 recommended.
Coolant:
Mercedes-Benz Specification 325.0 (Glysantin G48 or equivalent concentrate mixed 50/50 with distilled water).
Brake Fluid:
DOT 3 or DOT 4
Transmission Fluid Auto:
MB 236.1 specification (e.g., Dexron II or III compatible)
Known Issues
Cooling System:
Water pump leaks, radiator deterioration, thermostat failure, head gasket issues (especially with high mileage or poor maintenance).
Wear in ball joints, tie rod ends, control arm bushings, rear axle subframe mounts.
Body Corrosion:
Rust can be an issue, particularly in wheel arches, around windows, and underbody components if not properly maintained or if subject to harsh climates.
📚 Vehicle History
Brand Heritage
Manufacturer:
Daimler-Benz AG (later Daimler AG)
Model Evolution
W201 Introduction:
Introduced in 1982, the W201 was a revolutionary model for Mercedes-Benz, offering a more compact and affordable entry point into the brand.
Variants:
Initially launched as the 190 (with 1.8L petrol) and 190D (2.0L diesel). Later introduced 190E (2.0L, 2.3L, 2.6L petrol) and performance variants like the 190E 2.3-16 and 2.5-16 Cosworth.
Production
Production Period:
1982 - 1993
Production Locations
Manufacturing:
Primarily Bremen, Germany; also assembled in other locations worldwide.
🏆 Awards & Recognition
Recognitions
Auto Motor Und Sport Tests:
Consistently ranked highly in contemporary automotive reviews for its handling, build quality, and safety innovations compared to competitors.