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:...

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Taper: Car

Distributeur:

UGS: 194510

Mots clés: 190D 190E 2.5-16 1982 1983 1984 1985 1986 1987 1988 1989 1990 1991 1992 1993 260 Car Cars Mercedes Mercedes-benz Typ-201

Variantes de produits

Description

🏷️ Basic Information

Identification

Make:

Mercedes-Benz

Model:

Typ-201 (W201)

Common Name:

Body Style:

Limousine (Sedan)

Codes

Chassis Code:

👋 Introduction

Market Position

Segment:

Compact Executive Sedan

Introduction Year:

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:

📖 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:

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:

Height Mm:

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

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

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 Type:

API SG or higher, SAE 10W-40, 15W-40, or 5W-40 depending on climate (check manual for specific MB approval numbers)

Coolant Type:

MB Approved Antifreeze/Coolant (Glycol-based), typically a pink or blue concentrate mixed 50/50 with distilled water

Brake Fluid Type:

DOT 3 or DOT 4 (check specific vehicle recommendation)

Transmission Fluid Automatic:

MB 236.1 or 236.3 (e.g., Dexron II/III compatible)

Transmission Fluid Manual:

MB 235.1 (GL-4 gear oil)

Known Issues

Common Problems Engine:

Head gasket leaks, oil leaks from valve cover and oil pan, vacuum line deterioration, timing chain stretch (higher mileage), KE-Jetronic fuel distributor issues.

Common Problems Suspension:

Worn control arm bushings, worn ball joints, sagging springs, leaking shock absorbers.

Common Problems Electrical:

Wiring harness degradation (especially engine bay), faulty fuel pump relays, instrument cluster issues, vacuum operated central locking failures.

Common Problems Body:

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.