🏷️ Basic Information

Make:

Mercedes-Benz

Model:

190D

Year:

1987

Engine:

2.5L Turbo Diesel (OM602.961)

Chassis Code:

W201

Engine Code:

OM602.961

👋 Introduction

Segment:

Compact Executive Sedan / Diesel Car Segment

Target Audience:

Owners seeking to perform maintenance and repairs, independent repair shops, Mercedes-Benz enthusiasts.

Competitors 1987:

BMW 3 Series (E30), Audi 80/90, Volvo 240 Series, Saab 900.

Differentiation:

Mercedes-Benz build quality, diesel engine longevity and fuel economy, advanced (for its time) engineering, perceived safety and prestige.

Vehicle Signature:

Robust diesel powertrain, exceptional build quality, comfortable ride, discreet luxury.

Manual Value Proposition:

Empowers owners and technicians with comprehensive knowledge for maintaining and repairing a reliable classic Mercedes-Benz.

📋 Manual Details

Engine Mechanical:

Complete

Engine Electrical System:

Complete

Fuel System:

Complete

Transmission Manual:

Complete

Transmission Automatic:

Complete

Drivetrain:

Complete

Suspension:

Complete

Steering:

Complete

Brakes:

Complete

Body And Chassis:

Complete

Electrical System:

Complete

HVAC:

Complete

Interior Trim:

Complete

Exterior Trim:

Complete

Troubleshooting:

Comprehensive

Estimated Pages:

1000+

Type:

Workshop Repair Service Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine Systems:

Engine assembly, cylinder head, crankshaft, pistons, connecting rods, camshaft, valve train, timing, lubrication, cooling, turbocharger system, intake and exhaust manifolds, engine management (pre-common rail diesel electronics).

Fuel And Emissions:

Fuel injection pump (Bosch VE), injectors, fuel lines, fuel filter, glow plug system, emission control systems (Euro-specific where applicable).

Transmission And Drivetrain:

Manual transmission (4 and 5-speed), automatic transmission (4-speed 722.4), clutch, driveshafts, differential, rear axle.

Suspension And Steering:

Front and rear suspension (independent), shock absorbers, springs, control arms, ball joints, steering gear, power steering system, steering column.

Braking System:

Front and rear disc brakes, hydraulic system, brake fluid, master cylinder, proportioning valves, ABS (Anti-lock Braking System) components and diagnostics.

Electrical System:

Battery, alternator, starter motor, ignition system (pre-glow), lighting, wipers, horn, dashboard instruments, wiring diagrams, fuse box layout, power windows, central locking.

HVAC And Comfort:

Heating system, ventilation, air conditioning (if equipped), blower motor, climate controls.

Body And Interior:

Body panels, doors, hood, trunk, bumpers, glass, seals, interior trim panels, seats, dashboard assembly, headliner.

Maintenance Procedures:

Oil changes, filter replacements (oil, fuel, air), coolant flush, brake fluid flush, spark plug replacement (if applicable to any variant), belt adjustments and replacement, battery checks, tire rotation and balancing.

Repair Procedures:

Engine rebuild (top and bottom end), cylinder head gasket replacement, turbocharger overhaul, injection pump calibration, clutch replacement, transmission rebuild, brake caliper and disc replacement, suspension component replacement, steering rack repair, electrical component diagnosis and replacement, HVAC system repair.

Troubleshooting Guides:

Diagnostic flowcharts for common drivability issues, starting problems, overheating, braking issues, electrical faults, and HVAC malfunctions.

Specifications And Data:

Torque specifications for all fasteners, fluid capacities and types, engine timing data, emission control data, alignment specifications, electrical system resistance and voltage checks.

Depth Of Coverage:

Comprehensive, covering basic owner maintenance to complete engine and transmission overhauls. Includes detailed diagnostic procedures and troubleshooting trees.

Diagnostic Capabilities:

Advanced diagnostic procedures for the diesel injection system and associated electronics, as well as ABS system diagnostics. Emphasis on mechanical diagnostics specific to the OM602 engine.

Repair Detail:

Step-by-step instructions with accompanying diagrams and illustrations for most repair and maintenance tasks.

📊 Manual Specifications

File Type:

PDF

Searchability:

Searchable text content for quick information retrieval.

Printability:

Printable pages for workshop use.

Image Resolution:

High-resolution diagrams and illustrations.

Binding:

N/A (Digital Download)

Paper Quality:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Type:

Inline 5-Cylinder Turbocharged Diesel

Displacement:

2.5 Liters (2497 cc)

Bore X Stroke:

87.0 mm x 84.0 mm

Compression Ratio:

22.0:1

Horsepower:

126 hp @ 4,500 rpm (approx.)

Torque:

230 Nm @ 2,400 rpm (approx.)

Injection System:

Bosch VE Mechanical Injection Pump with Turbocharger and Intercooler

Fuel Type:

Diesel Fuel

Coolant Type:

Mercedes-Benz Specification (e.g., MB 325.0 or equivalent)

Engine Oil Capacity:

7.5 Liters (8.0 US Quarts) with filter change

Recommended Oil Viscosity:

API CD or CE rated, SAE 15W-40 or 10W-40 (depending on climate)

🔧 Transmission

Transmission Type Standard:

4-Speed Manual (M-B G3/25-5)

Transmission Type Optional:

4-Speed Automatic (722.4)

Clutch Type:

Hydraulically Actuated Single Dry Plate Clutch

Automatic Transmission Fluid:

MB Specification 236.1 (e.g., Dexron II)

Manual Transmission Fluid:

MB Specification 235.6 or 235.10 (e.g., SAE 75W-80 or 75W-90 GL-4)

📐 Dimensions

Length:

4,420 mm (174.0 in)

Width:

1,690 mm (66.5 in)

Height:

1,370 mm (53.9 in)

Wheelbase:

2,715 mm (106.9 in)

Curb Weight:

Approx. 1,300 - 1,350 kg (2,866 - 2,976 lbs) depending on options

Gross Vehicle Weight Rating:

Approx. 1,820 kg (4,012 lbs)

🛡️ Safety Features

NHTSA Ratings 1987:

No specific NHTSA ratings available for this model year; however, Mercedes-Benz vehicles of this era were known for robust construction and safety features for their time.

ABS:

Available (optional on some models, standard on later 2.5 Turbo variants)

Structure:

Reinforced safety cell, crumple zones.

Airbags:

Driver airbag optional/unavailable in 1987, not standard.

Seatbelts:

3-point front seat belts, 2-point rear lap belts (rear shoulder belts optional/later fitment).

💡 Technology Features

Audio System:

Optional factory AM/FM stereo with cassette player. Basic speaker setup.

Cruise Control:

Optional

Traction Control:

Not available on this model year.

Cellular Integration:

Not applicable.

🔧 Maintenance

Oil Change Interval:

10,000-15,000 km (6,000-9,000 miles) or 12 months, whichever comes first.

Fuel Filter Replacement:

30,000-40,000 km (18,000-25,000 miles)

Air Filter Replacement:

20,000-30,000 km (12,000-18,000 miles) or as needed based on conditions.

Coolant Flush:

Every 2-3 years or 60,000 km (37,000 miles)

Transmission Fluid Change Auto:

50,000-60,000 km (30,000-37,000 miles)

Transmission Fluid Change Manual:

70,000-90,000 km (43,000-56,000 miles)

Brake Fluid Type:

DOT 3 or DOT 4

Common Wear Items:

Front end components (ball joints, tie rod ends, control arm bushings), vacuum lines, vacuum operated headlight leveling system, pre-glow plug system reliability, door seal degradation.

Diesel Specific Concerns:

Injection pump seals, injector seals, timing chain wear (though generally robust), turbocharger seal leaks, potential for cylinder head cracking if severely overheated.

Electrical Gremlins:

Wiring harness insulation breakdown (especially in hot climates), faulty relays, instrument cluster issues.

📚 Vehicle History

Brand Legacy:

Mercedes-Benz, established in 1926, renowned for engineering excellence, luxury, and durability.

W201 Introduction:

Introduced in 1982 as the 'Baby Benz', designed to offer Mercedes-Benz quality and engineering in a more compact and affordable package.

190D 2.5 Turbo Introduction:

The 190D 2.5 Turbo (OM602.961 engine) was introduced in 1986/1987, offering a significant performance upgrade over the naturally aspirated diesel variants, becoming a popular choice for its blend of economy and capability.

Production Years W201:

1982-1993

Manufacturing Locations:

Mainly Germany, with some production in other global facilities.

🏆 Awards & Recognition

Critical Reception Era:

The W201 platform was critically acclaimed for its driving dynamics, build quality, and safety features, setting a new benchmark for compact executive sedans.

Modern Appreciation:

Considered a modern classic by enthusiasts for its longevity, fuel efficiency, and straightforward engineering, especially the OM602 engine.