Vehicle Segment:
Compact Executive Sedan
Key Competitors:
BMW 3 Series (E30), Audi 80, Volvo 240 Series, smaller Japanese luxury sedans.
Design Philosophy:
Robust engineering, high build quality, driver-focused ergonomics, a departure from Mercedes' traditionally larger vehicles.
Target Audience:
Younger professionals, those seeking Mercedes quality in a more compact and accessible package.
Engine:
Engine overhaul, tuning, fuel system, cooling system, lubrication system, air intake, exhaust system
Transmission:
Manual transmission, Automatic transmission, clutch system, transfer case (if applicable to 4MATIC variants)
Drivetrain:
Front axle, Rear axle, drive shafts, wheel hubs
Suspension Steering:
Front suspension, Rear suspension, steering system, level control (ADS, 4MATIC)
Brakes:
Brake system diagnostics, maintenance, hydraulic system, parking brake
Electrical:
Charging system, starting system, lighting, instrumentation, warning lamps
Body Chassis:
Body structure inspection, water leaks, corrosion, hinges, locks, sunroof, soft top, hood
HVAC:
Heating and ventilation, AC system (refrigerant charge, filters)
Routine Maintenance:
Oil and filter changes, air filter replacement, fuel filter replacement, V-belt inspection, coolant checks, tire pressure adjustments, battery checks
Engine Tuning:
Valve clearance adjustment, injection timing adjustment, idle speed adjustment, spark plug service
Transmission Service:
Fluid and filter changes for manual and automatic transmissions, clutch system checks
Brake Service:
Brake fluid replacement, brake pad and disc inspection, parking brake adjustment
Suspension Steering Service:
Ball joint inspection, axle oil level checks, steering play checks
Electrical Troubleshooting:
Lamp checks, indicator lamp functionality
Bodywork Lubrication:
Lubrication of door hinges, locks, mirrors, and hood mechanisms
Depth:
Comprehensive factory-level repair and diagnostic information, suitable for professional technicians and advanced DIYers.
Printability:
Printable pages, allowing users to create physical copies of relevant sections.
Binding:
N/A (Digital Download)
Paper Type:
N/A (Digital Download)
Feature:
Fully bookmarked and searchable for efficient information retrieval.
Source:
Official factory service manual, identical to what dealers use.
Condition:
Real files, not scanned copies, ensuring clarity and accuracy.
Engine Type:
Naturally Aspirated Diesel Inline-5
Displacement:
2.5 Liters (2497 cc)
Bore X Stroke:
87.0 mm x 84.0 mm
Compression Ratio:
22.0:1
Horsepower Ps:
90 PS (approx. 89 hp) @ 4600 rpm
Torque Nm:
159 Nm (approx. 117 lb-ft) @ 2800 rpm
Injection System:
Bosch Inline Injection Pump
Coolant Capacity:
Approx. 8.0 Liters (refer to manual for exact specifications)
Oil Capacity With Filter:
Approx. 7.0 Liters (refer to manual for exact specifications and fluid type)
Type:
5-Speed Manual Transmission
Type:
4-Speed Automatic Transmission (Optional)
Clutch Type:
Hydraulically Actuated Single Dry Plate Clutch
Automatic Transmission Fluid Capacity:
Approx. 7.5 Liters (refer to manual for specific type and exact capacity)
Length:
Approx. 4420 mm (174.0 in)
Width:
Approx. 1690 mm (66.5 in)
Height:
Approx. 1380 mm (54.3 in)
Curb Weight:
Approx. 1300-1400 kg (2866-3086 lbs) depending on options
Gross Vehicle Weight Rating:
Refer to vehicle VIN plate or manual
Crash Test Data:
N/A (Limited standardized crash testing in this era, known for robust build quality)
ABS:
Anti-lock Braking System (Optional on some models, standard on later ones)
Airbags:
Driver airbag typically standard from mid-generation onwards, passenger airbag optional.
Seat Belts:
Front and rear seat belts, manual check of operation covered in manual.
Engine Oil Change:
Typically every 7,500-10,000 miles or 12 months (refer to manual for specific recommendation based on driving conditions).
Transmission Oil Change Manual:
Recommended every 30,000-50,000 miles or as per manual. Fluid type: MB 235.1 or equivalent.
Transmission Fluid Change Automatic:
Recommended every 30,000-50,000 miles or as per manual. Fluid type: MB 236.3 or equivalent.
Engine Oil Specification:
API CD or CE, SAE 15W-40 or 10W-40 (refer to manual for precise viscosity and MB approval, e.g., MB-Approval 227.1)
Coolant Specification:
Glysantin G05 (or equivalent OAT coolant) mixed with distilled water at a 50/50 ratio.
Brake Fluid Specification:
DOT 3 or DOT 4 (refer to manual for specific MB approval, e.g., MB 331.0).
Diesel Injection System:
Injection pump timing drift, injector seal leaks, glow plug issues. The manual provides diagnostic procedures.
Suspension Components:
Worn control arm bushings, ball joints, and shock absorbers are common wear items. Manual details inspection and replacement.
Rust Corrosion:
Vulnerable areas include wheel arches, sills, and underbody. Manual covers corrosion inspection and preventative measures.
Mercedes Benz Legacy:
Established reputation for engineering excellence, durability, and luxury.
W201 Introduction:
Introduced in 1982, the W201 was Mercedes-Benz's first compact sedan, designed to appeal to a younger demographic and broaden their market reach.
190 D 2.5 Significance:
The 2.5-liter diesel variant offered a balance of fuel efficiency and Mercedes' renowned diesel durability. The OM602 engine was a development of the earlier OM601.
Production Period:
1982-1993 (W201 platform). This manual covers the 1986-1989 facelifted models.
