🏷️ Basic Information

Make:

Mercedes-Benz

Model:

190 D Turbo

Year:

1987

Chassis Code:

W201

Engine Code:

OM602.961

👋 Introduction

Market Segment:

Compact Executive Sedan / Diesel Segment

Target Audience:

Owners of the Mercedes-Benz 190 D Turbo (W201) seeking to perform maintenance, repairs, and restoration. Enthusiasts and independent workshops.

Key Competitors:

BMW E30 3 Series Diesel variants, Audi 80/90 Diesel variants, Volkswagen Passat Diesel variants.

Manual Strength:

Extreme detail, step-by-step instructions, inclusion of diagrams, illustrations, and wiring schematics, comprehensive coverage for all major repair and maintenance tasks.

Vehicle Key Selling Points:

Reliability, fuel efficiency, build quality, a precursor to the C-Class, distinctive styling.

📋 Manual Details

Main Systems Covered:

Engine, Fuel System, Cooling System, Exhaust System, Lubrication System, Drivetrain (Manual & Automatic Transmission, Rear Axle), Clutch, Suspension, Steering, Brakes, Electrical System, HVAC, Body & Chassis, Interior Components, Exterior Components

Estimated Page Count:

500+

Manual Type:

Factory Service Manual / Workshop Manual

Language:

English

Delivery Format:

Digital Download (PDF/WINRAR)

📖 Manual Coverage

Engine Mechanical:

Detailed procedures for disassembly, inspection, repair, and reassembly of the 2.5L Turbo Diesel OM602.961 engine, including cylinder head, pistons, connecting rods, crankshaft, camshaft, timing chain, oil pump, and more.

Fuel System:

Comprehensive coverage of the Bosch inline injection pump (VE type), injectors, fuel lines, fuel filter, fuel prefilter, fuel tank, and associated components. Includes procedures for checking injection timing and idle speed adjustments.

Cooling System:

Detailed instructions for coolant level checks, antifreeze protection, radiator, thermostat, water pump, heater core, and coolant replacement. Covers diagnosis of leaks and overheating issues.

Lubrication System:

Procedures for engine oil and filter changes, oil pressure checks, and inspection of oil passages.

Drivetrain Manual Transmission:

Procedures for manual transmission oil changes, checking and correcting oil levels, and clutch system inspection and fluid level checks.

Drivetrain Automatic Transmission:

Covers automatic transmission fluid and filter changes, and checking/correcting fluid levels. (Note: Specific automatic transmission variants may require additional verification).

Drivetrain Rear Axle:

Instructions for rear axle oil changes, checking and correcting oil levels, and rear axle mount adjustments.

Suspension And Steering:

Detailed inspection procedures for suspension components, ball joints (including use of special tools), and steering play. Includes tightening of steering bolts and front axle oil level checks.

Brake System:

Comprehensive brake system coverage including brake fluid level checks, brake line inspection, pad and disc thickness checks, parking brake adjustment, and brake fluid replacement. Includes brake test procedures.

Electrical System:

Wiring schematics are included, enabling troubleshooting and repair of the vehicle's electrical system, including lighting, warning lamps, and component function.

HVAC System:

Procedures for replacing dust filters for heating and ventilation, active charcoal filters, and recirculating air filters. Covers checking AC refrigerant charge and windshield washer fluid levels.

Body And Chassis:

Includes inspection of suspension and body structure, water leakage and corrosion inspection, cleaning of water drains, lubricating door hinges and locks, lubricating hood, and checking body for paint damage.

Wheels And Tires:

Procedures for inspecting and rotating wheels, inspecting tires, correcting tire pressure, and tightening wheel bolts.

Preventative Maintenance:

Engine oil and filter change, air filter replacement, fuel filter replacement, checking V-belts, checking coolant level, checking tire pressure, lubricating components.

Engine Repair And Tuning:

Valve clearance adjustment, injection timing adjustment, idle speed adjustment, spark plug inspection and replacement, intake and exhaust manifold seating inspection.

Drivetrain Maintenance:

Transmission fluid changes, differential fluid changes, clutch fluid checks, drive shaft flexible coupling inspection.

Brake Service:

Brake fluid replacement, parking brake adjustment, brake pad/disc inspection.

Suspension And Steering Service:

Ball joint inspection, steering play checks, level control system inspection (ADS, ASD, 4MATIC).

Electrical Troubleshooting:

Diagnosis and repair based on provided wiring schematics, inspection of warning lamps.

Bodywork And Cosmetic:

Corrosion inspection, water leak checks, lubrication of body components, paint damage assessment.

Depth Of Coverage:

Highly detailed, covering everything from basic fluid changes and inspections to complete engine rebuilds, transmission servicing, and chassis component overhauls. Designed for both DIY enthusiasts and professional mechanics.

📊 Manual Specifications

File Format Details:

Likely delivered as a compressed archive (WINRAR) containing a PDF file. PDF is typically searchable and printable. Compatibility spans multiple operating systems.

Print Quality Expectation:

Digital files typically offer high resolution, ensuring clarity of diagrams and text when printed.

Binding Type N:

N/A (Digital Download)

Paper Type N:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Type:

Inline-5 Cylinder Turbocharged Diesel

Engine Code:

OM602.961

Displacement:

2497 cc (2.5 Liters)

Bore X Stroke:

87.0 mm x 84.0 mm

Compression Ratio:

22.0:1

Power Output Hp:

94 hp (70 kW) @ 4600 rpm (approximate)

Torque Output Lb-Ft:

145 lb-ft (196 Nm) @ 2400 rpm (approximate)

0 60 Mph:

Approx. 12-13 seconds

Top Speed:

Approx. 110 mph (177 km/h)

Fuel Type:

Diesel

Injection System:

Bosch VE Rotary Injection Pump

Turbocharger:

Yes (Wastegated)

🔧 Transmission

Standard Transmission:

4-speed Manual (G5/17)

Optional Transmission:

4-speed Automatic (722.4)

Clutch Type:

Single dry plate clutch

📐 Dimensions

Length:

4420 mm (174.0 in)

Width:

1690 mm (66.5 in)

Height:

1390 mm (54.7 in)

Wheelbase:

2665 mm (104.9 in)

Curb Weight:

1290-1350 kg (2844-2976 lbs) (approximate, depending on transmission)

🛡️ Safety Features

Historical Safety:

While official ratings from modern bodies like IIHS/NHTSA for this era are scarce, Mercedes-Benz vehicles of this period were known for their robust build quality and safety engineering, including crumple zones.

Active Safety Features:

Four-wheel disc brakes (front ventilated), power steering, optional ABS (Anti-lock Braking System).

Passive Safety Features:

Reinforced safety cage, impact-absorbing steering column, front and side-impact beams, seat belts.

💡 Technology Features

Infotainment System:

Basic in-dash radio/cassette player with manual tuning and speaker controls. Some models may have had upgraded sound systems.

Driver Assistance Features:

Optional ABS (Anti-lock Braking System), optional ASD (Automatic Slip Differentials) on some rear-wheel-drive models.

Connectivity Options:

Limited to antenna mast for radio reception.

🔧 Maintenance

Oil Change Interval:

Typically every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, depending on driving conditions. Consult manual for specifics.

Air Filter Replacement:

Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on dust levels.

Fuel Filter Replacement:

Every 15,000-30,000 miles (24,000-48,000 km).

Coolant Replacement:

Every 2-3 years or 30,000-60,000 miles (48,000-96,000 km).

Valve Adjustment:

Check and adjust periodically, typically every 30,000-60,000 miles (48,000-96,000 km), as specified in the manual.

Engine Oil Specification:

API CD or ACEA E1/E2 grade for diesel engines. Viscosity typically 10W-40 or 15W-40 (check manual for precise recommendation).

Coolant Specification:

MB-Approval 325.0 or equivalent G48 ethylene glycol-based coolant (typically blue/green). Mixture of 50% coolant and 50% distilled water.

Transmission Oil Manual:

MB 235.1 spec, e.g., SAE 75W-85 or 75W-90 GL-4 gear oil.

Transmission Oil Automatic:

MB-Approval 236.2 spec, e.g., Dexron II D or equivalent ATF.

Rear Axle Oil:

MB 235.0 spec, e.g., SAE 80W-90 GL-5 hypoid gear oil.

Brake Fluid:

DOT 3 or DOT 4, complying with Mercedes-Benz specifications.

Common Wear Items:

Glow plugs, fuel injectors, V-belts, vacuum lines, suspension bushings, ball joints, exhaust system components, and potential for rust in certain areas if not maintained.

Diesel Specific Concerns:

Injection pump calibration, injector fouling, pre-chamber issues (less common on this model but possible), glow plug system reliability.

📚 Vehicle History

Mercedes Benz Legacy:

Mercedes-Benz has a long-standing reputation for engineering excellence, luxury, and durability, particularly in its diesel engines.

W201 Introduction:

The W201 (190 series) was introduced in 1982 as Mercedes-Benz's entry into the compact executive segment, offering traditional Mercedes quality in a smaller package. The 190 D Turbo variant arrived later, enhancing performance and drivability.

Production Years:

1982-1993 (W201 chassis)

190 D Turbo Introduction Year:

1983 (initially as 190 D 2.2 Turbo, evolving to 190 D 2.5 Turbo)

🏆 Awards & Recognition

Model Recognition:

While specific awards for the 190 D Turbo 2.5 are not widely documented in the same way modern cars are, the W201 series itself was critically acclaimed for introducing a new segment for Mercedes-Benz and for its engineering quality, influencing future compact luxury sedans.