Positioning:
The Mercedes-Benz 190 series (W201) was a pivotal model that introduced Mercedes-Benz's engineering and luxury to a broader market segment, often referred to as the 'Baby Benz'. This manual caters to enthusiasts and owners maintaining these durable vehicles.
Competitors:
Competed against entry-level luxury sedans and well-equipped mid-size sedans from brands like BMW (3 Series), Audi (80/90), Volvo (740/760), and Saab.
Vehicle Highlights:
Known for robust build quality, exceptional durability, excellent ride comfort, and sophisticated engineering, particularly the efficient and reliable diesel engines.
General Coverage:
Complete service, repair, diagnostics, and maintenance for all specified Mercedes-Benz 190 models.
Estimated Page Count:
Over 1000 pages (typical for comprehensive workshop manuals covering multiple variants).
Type:
Workshop Service Repair Manual
Format:
Downloadable Digital Format (likely PDF)
Engine:
Diesel engine systems (OM601, OM602, OM603 variants), including fuel injection, cooling, lubrication, emissions control.
Transmission:
Manual and automatic transmission systems, driveline, clutch, differentials.
Brakes:
Hydraulic brake systems, ABS (if equipped), parking brake, brake component overhaul.
Suspension Steering:
Front and rear suspension systems, steering gear, power steering, wheel alignment.
Electrical:
Complete electrical system, wiring diagrams, lighting, ignition, starter, charging system, instruments, comfort systems.
Body Chassis:
Body construction, doors, windows, interior trim, body repair, chassis components.
HVAC:
Heating, ventilation, and air conditioning systems (HVAC).
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, inspections.
Diagnostics:
Troubleshooting guides, diagnostic fault codes (if applicable), symptom-based diagnostics.
Repair Overhaul:
Detailed step-by-step procedures for component removal, disassembly, repair, reassembly, and installation.
Specifications:
Torque specifications, clearances, tolerances, measurements, and adjustment procedures.
Special Tools:
Identification and usage of specialized tools required for specific repairs.
Depth:
Comprehensive, from basic fluid checks and component replacement to complete engine and transmission rebuilds, including electrical system troubleshooting and bodywork.
190D/Db:
OM601 inline-four cylinder diesel engine. Displacement typically 1.8L (OM601.911) or 2.0L (OM601.912).
190Sl:
This designation is unusual for a diesel model. 'SL' typically denotes a roadster. If referring to a petrol 190 (W201) that might be confused, common petrol engines included M102 (2.0L, 2.3L, 2.6L). Assuming '190SL' here might be a typo or referring to a specific regional variant or early petrol models.
190D (Om601.912 2.0L):
Approx. 72-75 HP @ 4600 RPM, 100-105 lb-ft Torque @ 2800-3000 RPM.
190D (Om601.911 1.8L):
Approx. 55 HP @ 4600 RPM, 80 lb-ft Torque @ 2600 RPM.
Diesel Injection:
Mechanical Bosch inline injection pump (e.g., Bosch VE) with direct injection (pre-chamber or direct depending on specific OM601 variant). Glow plug system for cold starting.
Type:
Thermostatically controlled liquid cooling system with belt-driven water pump and fan.
Oil Type Capacity:
Requires specific diesel engine oil, e.g., API CD or higher. Capacity approximately 6.0-6.5 liters. Refer to manual for exact API classification and viscosity.
Transmission Type 190D:
4-speed or 5-speed manual transmission.
Transmission Type 190D Optional:
4-speed or 5-speed automatic transmission (e.g., 722.4).
Manual Transmission Oil:
Manual gearbox oil specification (e.g., MB 235.1, SAE 75W-90 or 80W-90). Capacity around 1.5-2.0 liters.
Automatic Transmission Fluid:
Automatic transmission fluid specification (e.g., MB 236.1 or 236.3). Capacity around 7-8 liters for a complete fluid change (including torque converter).
Wheelbase:
Approximately 2670 mm (105.1 inches).
Overall Length:
Approximately 4420 mm (174.0 inches).
Overall Width:
Approximately 1690 mm (66.5 inches).
Overall Height:
Approximately 1380 mm (54.3 inches).
Curb Weight:
Varies by model and equipment, typically around 1250-1350 kg (2750-2975 lbs).
Gross Vehicle Weight Rating:
Typically around 1800-1900 kg.
Crash Safety Reputation:
The W201 chassis was renowned for its structural integrity and safety for its era, featuring a very strong passenger cell and crumple zones. ABS was an optional feature on many models.
Anti Lock Brakes:
Optional ABS system.
Airbags:
Driver's airbag became available as an option later in the W201's lifecycle.
Seatbelts:
Pre-tensioner seatbelts for front occupants often standard or optional, depending on year and market.
Radio Options:
Factory options included AM/FM radio, cassette players, often with multi-speaker systems. Aftermarket head units are common upgrades.
Cruise Control:
Optional cruise control system available on many models.
Central Locking:
Vacuum-actuated central locking system was a common feature, known for potential vacuum leaks causing malfunctions.
Oil Change Interval:
Typically every 7,500 to 15,000 km (4,600 to 9,300 miles) or 12 months, depending on driving conditions and oil specification used. Refer to manual for specific recommendations.
Fuel Filter Replacement:
Recommended replacement every 30,000-50,000 km (18,000-30,000 miles) or annually.
Air Filter Replacement:
Recommended replacement every 15,000-30,000 km (9,300-18,000 miles) or as needed based on operating environment.
Coolant Type:
Mercedes-Benz approved antifreeze/coolant concentrate (e.g., MB 325.0 or 326.0) mixed with deionized water. Typically a 50/50 mix.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid. Must be replaced every 2-3 years due to hygroscopic nature.
Diesel Specific Issues:
Glow plug system failures, injector pump issues, timing chain wear (check tensioner), injector seal leaks, vacuum leak issues affecting door locks and central locking.
General Wear Items:
Front suspension bushings and ball joints, rear axle mountings, HVAC blower motor, fuel lines (can become brittle), wiring harness insulation degradation.
Engine Mounts:
Replacement of engine and transmission mounts is common due to age and mileage.
Mercedes Benz Legacy:
Mercedes-Benz has a long-standing reputation for engineering excellence, durability, and safety, established through its luxury sedans and robust commercial vehicles.
W201 Introduction:
Introduced in 1982, the W201 (190 series) was Mercedes-Benz's first compact executive car. It was designed to be a more accessible entry point into the brand while retaining core Mercedes-Benz values. The diesel variants (190D, 190D 2.5) were highly popular for their fuel efficiency and longevity.
Diesel Engine Development:
The OM601 diesel engine family, introduced with the W201, was a significant advancement in diesel technology, known for its quiet operation and reliability. Later models saw OM602 five-cylinder diesel engines and even turbocharged versions (e.g., 190D 2.5 Turbo).
Production Years:
1982 - 1993 (W201 platform).
Manufacturing Location:
Primarily Bremen, Germany.
Design Award:
The W201's design, by Bruno Sacco, is widely praised for its timeless elegance and aerodynamic efficiency, influencing subsequent Mercedes-Benz designs.
Durability Reputation:
Consistently ranked among the most durable and reliable vehicles produced, with many examples exceeding 300,000 to 500,000 miles with proper maintenance.
