Segment:
Compact Executive Sedan (E-Segment)
Key Competitors:
BMW 3 Series (E30), Audi 80/90, Saab 900
Design Philosophy:
Robust engineering, aerodynamic efficiency, high build quality, focus on safety and comfort for its class.
Chassis Design:
Monocoque construction, independent suspension on all wheels (multi-link rear introduced later), front MacPherson struts.
Aerodynamics:
Pioneered aerodynamic design in its class, contributing to fuel efficiency and stability. Drag coefficient of approximately 0.32.
Model Variants Covered:
Mercedes-Benz W201 190, 190E, 190D
Engine Variants Covered:
2.3L M102, 2.6L M103, 2.3L OM601, 2.9L OM602
Estimated Page Count:
Comprehensive (Exact count not provided, typical for this era of manual is 800-1500 pages)
Manual Type:
Workshop Service Repair Manual
Language:
English (Assumed, typical for international sales)
Powertrain:
Engine (crankcase, cylinder head, crankshaft assembly, timing, valvetrain, fuel injection, air filter, belt drive, manifolds, emission control, lubrication, cooling, suspension), Fuel System, Exhaust System
Drivetrain:
Propeller Shaft
Chassis Suspension Steering Brakes:
Chassis Suspension System, Front Axle, Rear Axle, Wheels, Brakes (Hydraulic and Mechanical), Brakes Vacuum System, Steering
Electrical Systems:
Electrical System Engine, Electrical System, Electrical System of Body
Body Interior Accessories:
Glass and Windows, Interior Equipment, Doors, Sliding Roof, Central Locking System, Detachable Body Components, Seats, Restraint Systems
Accelerator Control Cruise Control Electrical Accelerator:
Diagnosis and repair of throttle linkage, cruise control systems (vacuum or electronic), and related electrical components.
Central Locking System Coverage:
Diagnosis and repair of vacuum-operated or electric central locking systems, actuators, and control modules.
Maintenance Procedures:
Scheduled maintenance, fluid changes, filter replacements, inspections
Diagnostic Procedures:
Troubleshooting guides, fault diagnosis for various systems
Repair Procedures:
Detailed step-by-step repair instructions for all major components and systems
Adjustment Procedures:
Calibration and adjustment of fuel injection, brakes, steering, etc.
Electrical System Diagnosis:
Wiring diagrams, component testing, troubleshooting procedures for engine, body, and chassis electrical systems.
Technical Depth:
Comprehensive, covering basic maintenance to advanced engine and chassis overhauls. Includes torque specifications, tolerances, and detailed diagrams.
M102 Engine Variant 2.3L:
2.3L Inline-4, SOHC, Fuel Injection (CFI or KE-Jetronic depending on sub-model and year)
M103 Engine Variant 2.6L:
2.6L Inline-6, SOHC, Fuel Injection (KE-Jetronic)
Om601 Engine Variant 2.3L:
2.3L Inline-4 Diesel, SOHC, Indirect Injection (Diesel)
Om602 Engine Variant 2.9L:
2.9L Inline-5 Diesel, SOHC, Indirect Injection (Diesel)
Engine Cooling System Coverage:
Radiator, water pump, thermostat, hoses, fan clutch, expansion tank, coolant type and capacity.
M102 2.3L Power:
Approx. 130-140 hp (varies by spec and year)
M103 2.6L Power:
Approx. 160-165 hp
Fuel Injection Systems Covered:
Continuous Fuel Injection (CFI), Bosch KE-Jetronic (Mechanical-Electronic Fuel Injection)
Casing And Cylinder Head Coverage:
Detailed procedures for disassembly, inspection, machining, and reassembly of engine blocks and cylinder heads.
Crankshaft Assembly Coverage:
Inspection, balancing, bearing replacement, and installation procedures for crankshaft, connecting rods, and pistons.
Engine Timing Valvetrain Coverage:
Camshaft timing, valve lash adjustment, chain/belt replacement, valve guide and seal replacement.
Emission System Coverage:
Component identification, testing, and repair of emission control devices and associated plumbing.
Standard Transmission:
4-speed manual (early models), 5-speed manual (later models)
Optional Transmission:
4-speed automatic, 5-speed automatic (e.g., 722.4, 722.5)
Transmission Fluid Type:
MB 236.1 or 236.3 Automatic Transmission Fluid (ATF), Manual transmission fluid varies (e.g., MB 235.1)
Passive Safety Features:
Reinforced safety cell, energy-absorbing crumple zones, padded interior surfaces, seat belts
Active Safety Features:
Four-wheel disc brakes (ABS optional on later models), precise steering system
Restraint Systems:
Standard three-point seatbelts, optional driver's side airbag (late models)
Infotainment Features:
Basic analog radio (AM/FM), optional cassette player. Limited by era.
Driver Assistance Features:
ABS (optional on later models), Cruise Control (optional on some variants).
Connectivity:
N/A (No integrated modern connectivity features)
Oil Change Interval:
Typically 10,000-15,000 km (6,000-9,000 miles) or 1 year, depending on engine and driving conditions.
Transmission Fluid Service:
Check every 20,000-30,000 km, replace every 40,000-60,000 km (automatic)
Engine Oil Specification:
MB 229.1 or API SJ/SL (e.g., SAE 10W-40, 15W-40, 5W-40 depending on climate)
Coolant Specification:
MB 325.0 or equivalent (e.g., ethylene glycol based with corrosion inhibitors)
Brake Fluid Specification:
DOT 4
Manual Transmission Fluid Type:
Hypoid gear oil, API GL-4 or GL-5 (e.g., MB 235.1)
Common Issues:
Headliner sagging, heater blower motor failure, vacuum line leaks (affecting central locking/HVAC), rust (especially around wheel wells, sills, and sunroof), fuel distributor issues (KE-Jetronic), worn suspension bushings, crankshaft position sensor failure (later models).
Diesel Engine Specific Issues:
Glow plug issues, injector pump problems, potential for overheating if cooling system is neglected.
Brand Focus:
Engineering excellence, durability, luxury, innovation.
Design Inspiration:
Pioneering a more compact and accessible Mercedes-Benz while retaining core brand values. Influenced by aerodynamic principles. Bruno Sacco design.
Target Market:
Introduced as a more affordable entry-level Mercedes-Benz, attracting younger buyers and expanding market reach.
Production Facilties:
Primarily Germany (Sindelfingen), also South Africa and other CKD assembly plants.
Total Production Units:
Over 1.5 million units
