Mercedes-Benz Typ-201 Limousine (190D bis 190E 2.5-16) Workshop Service Repair Manual 1982-1993 (DE) (3 000+ Pages 635MB Searchable Bookmarked iPad-ready)
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🏷️ Basic Information Identification Make: Mercedes-Benz Model: Typ-201 (W201) Common Name: 190 Body Style: Limousine (Sedan) Codes Chassis Code: W201 👋 Introduction Market Position Segment: Compact Executive Sedan Introduction Year: 1982 Competitive Analysis Competitors: BMW 3 Series (E30), Audi 80/90, Volvo 240, Ford Sierra Key Features Design Philosophy: Robust engineering, build quality, safety, and understated luxury synonymous with Mercedes-Benz Innovations: Introduced multi-link rear suspension, advanced safety features for its class 📋 Manual Details Coverage Areas Engine Variants Covered: 190D (Diesel), 190E (Petrol), 190E 2.3-16, 190E 2.5-16 Production Years Covered: 1982-1993 Page Count Total Pages: 3000+ Manual Type Type: Workshop Service Repair Manual Language Language: German Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine disassembly, assembly, inspection, and repair for all variants Engine Control System: Diagnosis and repair of electronic engine management systems (KE-Jetronic, etc.) Fuel System: Fuel injection system (Bosch KE-Jetronic and others), fuel pumps, injectors, lines Cooling System: Radiator, water pump, thermostat, coolant hoses, fan systems Lubrication System: Oil pump, oil filter, oil pan, lubrication passages Ignition System: Spark plugs, ignition coils, distributors, timing Exhaust System: Exhaust manifolds, catalytic converters (where applicable), mufflers, pipes Transmission Manual: Manual transmission repair, clutch system, linkages Transmission Automatic: Automatic transmission repair, torque converter, valve body, electronic control Drive Shaft And Differential: Drive shafts, universal joints, rear axle, differential case assembly Suspension Front: MacPherson struts, control arms, bushings, springs, shock absorbers Suspension Rear: Multi-link independent rear suspension, trailing arms, springs, shock absorbers Steering System: Power steering pump, steering gear, steering column, linkages Brake System Front: Disc brakes, calipers, pads, rotors, brake lines Brake System Rear: Disc brakes, calipers, pads, rotors, brake lines Brake Actuation And Booster: Brake master cylinder, brake booster, ABS system (where applicable) Electrical System Charging: Alternator, voltage regulator, battery, starter motor Electrical System Starting: Starter motor, ignition switch, starter relay Lighting System: Headlights, taillights, interior lighting, wiring Instrumentation And Gauges: Combination meter, warning lights, diagnostics Windshield Wiper And Washer: Wiper motor, linkages, blades, washer pump, nozzles Power Accessories: Power windows, power locks, sunroof control Supplemental Restraint System Srs: Airbags (driver, passenger), seat belt pre-tensioners, SRS control modules Body And Chassis: Body repair, rust prevention, structural components Body Panels And Trim: Doors, fenders, hood, trunk lid, bumpers, interior and exterior trim HVAC System: Heating, ventilation, and air conditioning (HVAC) system components and repair Emission Control Systems: Catalytic converters, EGR systems, charcoal canisters, emission related sensors Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, lubrication Troubleshooting: Diagnostic procedures for all systems, common fault finding Repair And Rebuild: Detailed step-by-step instructions for component repair and complete system overhauls Component Disassembly Assembly: Complete breakdown and reassembly of all major and minor components Wiring Diagrams: Comprehensive electrical wiring diagrams for all circuits Torque Specifications: Precise torque values for all fasteners and critical components Special Tools: Identification and usage of specialized tools required for specific repairs Technical Depth Depth: Comprehensive, covering basic maintenance to full engine and transmission rebuilds 📊 Manual Specifications File Format Type: Searchable PDF Size Mb: 635 Print Quality Printability: Fully printable Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) Navigation Features: Bookmarked, iPad-ready ⚙️ Engine Specifications Primary Engine Engine Code Example Diesel: OM601 (2.0L Diesel), OM602 (2.5L Diesel) Engine Code Example Petrol: M102 (2.0L, 2.3L Petrol), M102 E23-2.3-16, M102 E25-2.5-16 Performance Power Output Range: 70 hp (190D) to 235 hp (190E 2.5-16 Evolution II) Torque Output Range: 130 Nm (190D) to 335 Nm (190E 2.5-16 Evolution II) Fuel System Injection System Petrol: Bosch KE-Jetronic (mechanically controlled electronic fuel injection) Injection System Diesel: Bosch VE Rotary Injection Pump Engine Layout Layout: Inline-4, Inline-5 (Diesel), Inline-4 (Petrol variants) 🔧 Transmission Standard Transmission Type Standard: 4-speed Manual (early models), 5-speed Manual (later models) Optional Transmission Type Optional: 4-speed Automatic (722.4), 5-speed Automatic (722.5, later models) Features Automatic Features: Economy and Sport modes on some automatic transmissions 📐 Dimensions Exterior Length Mm: 4420 (early), 4445 (late) Width Mm: 1690 Height Mm: 1390 Weights Curb Weight Kg Range: 1200 - 1450 🛡️ Safety Features Ratings Crash Test Info: Early models benefited from Mercedes-Benz's renowned safety engineering; later models incorporated ABS and driver airbags. Active Features ABS: Available on later models and specific trims (e.g., 190E 2.3-16, 2.5-16) Passive Features Airbags: Driver airbag became available on later models, passenger airbag optional/standard on some trims 💡 Technology Features Infotainment Original Infotainment: Factory-installed analog radio/cassette players, often with power antenna. Driver Assistance ABS: Anti-lock Braking System availability varied by model year and trim. Connectivity Early Features: Power windows, power mirrors, central locking (often vacuum operated), cruise control (optional/standard on some models). 🔧 Maintenance Service Intervals Oil Change Interval Km: Typically 10,000 - 15,000 km (depending on oil type and driving conditions) Major Service Interval Km: Approximately 40,000 - 60,000 km for spark plugs, fuel filters, air filters, etc. Fluid Specifications Engine Oil...
Rust, particularly in wheel arches, rocker panels, and under battery tray. Door seals, window seals can degrade.
📚 Vehicle History
Brand Heritage
Legacy:
Part of Mercedes-Benz's move to create a more accessible, yet still premium, compact car
Model Evolution
Introduction Context:
Designed by Bruno Sacco, the W201 was a radical departure, aiming to combine Mercedes-Benz quality and safety in a smaller, more affordable package.
Sporting Variants:
The 190E 2.3-16 and 2.5-16 Cosworth variants were developed in conjunction with Cosworth and were homologation specials for touring car racing (DTM).
Production
Production Locations:
Bremen, Germany; East London, South Africa
Production Volume:
Over 1.8 million units produced during its lifespan.
🏆 Awards & Recognition
Recognitions
Automotive Journalism:
Widely praised for its build quality, durability, and driving dynamics, especially the performance variants. Often cited as a 'baby Benz' that redefined entry-level luxury.