🏷️ Basic Information

Make:

Mercedes-Benz

Model:

190 (W201)

Sub Models Covered:

190, 190D, 190DB, 190SL

Product Name:

Mercedes Benz 190 190D 190DB 190SL Complete Workshop Service Repair Manual

👋 Introduction

Introduction:

The Mercedes-Benz 190 (W201) was a pivotal model that redefined the compact executive sedan segment, offering Mercedes-Benz engineering and quality at a more accessible price point. This manual is essential for owners and independent mechanics aiming to maintain and repair these enduring vehicles.

Introduction:

Competed against luxury compacts like the BMW 3 Series, Audi 80/90, and Volvo 240 series. Its robust build, advanced suspension, and range of efficient engines (especially the diesel variants) set it apart.

Introduction:

The W201 was praised for its over-engineered construction, sophisticated multi-link rear suspension, and solid safety features for its time. This manual captures that meticulous design, providing detailed guidance for its upkeep.

📋 Manual Details

Manual Type:

Complete Workshop Service Repair Manual

Language:

English

Format:

Digital Downloadable (PDF)

All Models Covered:

Yes (All Models, Engines, Trim, Transmissions)

Page Count:

Estimated 1000+ pages (typical for comprehensive workshop manuals of this era)

📖 Manual Coverage

Engine Mechanical:

Engine assembly, disassembly, tuning, lubrication, cooling, fuel injection systems (gasoline and diesel), emissions control

Engine Electrical:

Ignition system, starting system, charging system, ECU diagnostics and repair

Transmission:

Manual and automatic transmission overhaul, clutch system, torque converter

Drivetrain:

Driveshafts, axles, differentials

Suspension:

Front and rear suspension components, shock absorbers, springs, alignment specifications

Steering:

Steering gearbox, power steering system, steering column

Brakes:

Brake system components, hydraulic system, ABS (if applicable), disc and drum brake repair

Electrical System:

Wiring diagrams, lighting, instrumentation, power windows, central locking, wiper system

Bodywork And Chassis:

Body panel repair, interior trim, glass replacement, welding procedures

HVAC:

Heating, ventilation, and air conditioning system service and repair

Fuel System Diesel:

Diesel fuel injection system components, troubleshooting, and repair for OM601 and OM602 engines.

Exhaust System:

Components, inspection, and replacement of exhaust manifolds, pipes, catalytic converter, and mufflers.

Cooling System:

Radiator, water pump, thermostat, hoses, and fan service and replacement.

Wheel Hub Bearings:

Inspection, replacement, and adjustment of wheel bearings.

Maintenance:

Scheduled maintenance, oil changes, filter replacements, tune-ups

Diagnostics:

Troubleshooting guides, symptom analysis, diagnostic flowcharts

Repair:

Component removal, installation, adjustment, and overhaul

Rebuild:

Complete engine and transmission rebuild procedures

Wiring Diagrams:

Detailed electrical schematics for all systems

Torque Specifications:

Precise torque values for all fasteners

Special Tools:

Identification and use of specialized tools

Cylinder Head Removal:

Step-by-step guide for removing and reinstalling cylinder heads, including torque sequences.

Suspension Alignment:

Specifications and procedures for front and rear wheel alignment, camber, caster, and toe angles.

Electrical Troubleshooting:

Systematic approach to diagnosing electrical faults using wiring diagrams and multimeter readings.

Body Repair Welding:

Guidance on common body rust repairs, including welding techniques and preparation for painting.

Brake Bleeding:

Procedures for bleeding hydraulic brake systems, including those with ABS.

Depth:

Comprehensive (from basic maintenance to complete engine/transmission rebuilds)

Fuel Pump Replacement:

Detailed steps for replacing mechanical and electric fuel pumps, including pressure testing.

Injector Service Diesel:

Procedure for removing, testing, and replacing diesel injectors.

Timing Belt Chain:

Information on timing chain replacement (M102, M103) and procedures for ensuring correct timing alignment.

Differential Service:

Rear differential fluid change, seal replacement, and overhaul procedures.

Engine Rebuild Specs:

Piston ring gap, bearing clearance, valve seat angles, and other critical internal engine specifications for rebuilding.

Ignition Timing:

Setting and verifying ignition timing for gasoline engines.

📊 Manual Specifications

File Format:

PDF

Searchable Text:

Likely searchable if OCR applied, otherwise image-based

Print Quality:

High quality, clear text and legible diagrams

Binding Type:

Digital (no physical binding)

Paper Type:

Digital (no physical paper)

Device Compatibility:

All PC & MAC Computers, tablets, mobile phones

Software Requirements:

Adobe Reader (free download)

Printing Options:

Printable by page, chapter, or entire manual

⚙️ Engine Specifications

Engine Family:

M102 (Gasoline), OM601 (Diesel), OM602 (Diesel)

Gasoline Engines:

190: 2.0L (1997cc) I4 (M102.910), 190E: 2.3L (2299cc) I4 (M102.985), 190E 2.6: 2.6L (2597cc) I6 (M103.942)

Diesel Engines:

190D: 2.0L (1997cc) I4 Diesel (OM601.912), 190D 2.5: 2.5L (2497cc) I5 Diesel (OM602.912)

Diesel Turbo:

190D 2.5 Turbo: 2.5L (2497cc) I5 Turbo Diesel (OM602.962)

Gasoline Hp Range:

Approx. 90-147 hp depending on engine variant

Diesel Hp Range:

Approx. 70-90 hp (naturally aspirated), 125 hp (turbo)

Gasoline Fuel Delivery:

Carburetor (some early models) or Bosch K-Jetronic/KE-Jetronic fuel injection

Diesel Fuel Delivery:

Bosch inline injection pump or rotary injection pump

🔧 Transmission

Standard Transmission:

4-speed or 5-speed manual transmission

Optional Transmission:

4-speed or 5-speed automatic transmission (722.4 series)

Transmission Features:

Overdrive gear in 5-speed manual and automatic transmissions for improved fuel economy and reduced engine noise.

📐 Dimensions

Length:

Approx. 4420-4445 mm (depending on model/year)

Width:

Approx. 1690-1700 mm

Height:

Approx. 1370-1390 mm

Curb Weight:

Approx. 1250-1450 kg (depending on engine and equipment)

Gross Vehicle Weight:

Varies by model, consult manual for specific values

🛡️ Safety Features

Safety Features Era:

Advanced for its time, including a stronger passenger safety cell, crumple zones, and energy-absorbing steering column.

Active Safety:

Anti-lock Braking System (ABS) available on many models.

Passive Safety:

Driver and front passenger airbags (optional on many early models, standard on later ones), seatbelt pre-tensioners.

💡 Technology Features

Infotainment Systems:

Basic analog radio, cassette player. Analog climate controls, manual or electric window regulators.

Driver Assistance:

Cruise control (optional), ABS (optional on many models).

Connectivity:

Limited by era; no built-in Bluetooth or USB. Antenna for radio reception.

🔧 Maintenance

Oil Change Interval:

Typically every 5,000-10,000 miles (8,000-15,000 km) or 6-12 months, depending on driving conditions and oil used.

Major Service Interval:

Spark plugs, fuel filter, air filter, transmission fluid service typically at 30,000-60,000 mile intervals. Detailed schedule in manual.

Engine Oil Gasoline:

API SG or higher, SAE 10W-40 or 15W-40 typically recommended (check specific engine and climate).

Engine Oil Diesel:

API CF or higher, SAE 15W-40 or 10W-40 typically recommended for naturally aspirated diesels; consult manual for turbo diesel variants.

Coolant:

Ethylene glycol-based coolant meeting MB-Approval 325.0 specifications, typically a 50/50 mix with distilled water.

Brake Fluid:

DOT 3 or DOT 4 (check manual for specific MB approval, e.g., 331.0 or 332.0)

Transmission Fluid Auto:

MB-specific automatic transmission fluid (e.g., ATF 3403 or successor, check manual for exact type matching the 722.4 gearbox)

Transmission Fluid Manual:

GL-4 gear oil (e.g., SAE 75W-90 or 80W-90, check manual for precise specification)

Known Issues:

Head gasket leaks (M102/M103), vacuum line deterioration, differential mounts, rust on common areas (wheel arches, sills), climate control flap issues, front suspension ball joint wear.

Diesel Specific Issues:

Glow plug issues, injection pump leaks, injector problems, turbocharger maintenance (if applicable).

📚 Vehicle History

Brand Heritage:

Mercedes-Benz has a long-standing reputation for engineering excellence, durability, and safety, established over decades prior to the 190's introduction.

Model Evolution:

Introduced in 1982 as the 'Baby Benz', it was developed under Bruno Sacco's design leadership. It underwent several facelifts and powertrain updates throughout its production run (1982-1993).

Production Years:

1982-1993

Production Plants:

Bremen, Germany; also assembled in other locations globally.

🏆 Awards & Recognition

Recognitions:

Widely acclaimed for its build quality and engineering. Often referred to as the 'over-engineered' compact car. Praised for its durable diesel engines.

Ratings:

Consistently ranked highly for reliability and longevity by automotive publications of its era.