🏷️ Basic Information

Make:

Mercedes-Benz

Model:

190 D

Engine Variant:

2.2 Diesel

W201:

Generation 1

Chassis Code:

W201

👋 Introduction

Segment:

Compact Executive Sedan

Reputation:

Known for its robust build quality, reliability, and advanced engineering for its era.

Competitors:

BMW 3 Series (E30), Audi 80, Volvo 240

Chassis Design:

W201 platform, praised for its advanced independent rear suspension and independent front suspension.

Diesel Engine Offering:

Offered a reliable and fuel-efficient diesel option, appealing to a segment prioritizing economy and longevity.

Dealer Parity:

Provides the same information used by Mercedes-Benz dealerships for servicing and repairs.

Accessibility:

Instant download facilitates immediate access for DIY mechanics and professional technicians.

📋 Manual Details

Years Covered:

1986, 1987, 1988, 1989

Specific Models:

Mercedes-Benz 190 D 2.2 (W201 Chassis)

Estimated Pages:

Extensive (Exact number not specified, but described as 'complete' and 'comprehensive')

Type:

Factory Service and Repair Manual

Language:

English

Format:

Digital Download (PDF)

📖 Manual Coverage

Engine:

Diesel engine (OM601 variant), fuel system, lubrication, cooling, exhaust, intake, timing, emissions components (Oxygen Sensor)

Transmission:

Manual transmission, Automatic transmission, Transfer case (if applicable to specific 4MATIC variants)

Drivetrain:

Front axle, Rear axle, Drive shaft flexible coupling, Wheel bolt tightening

Suspension Steering:

Suspension and body structure inspection, Level control (ADS, 4MATIC), Self-leveling suspension, Steering play, Steering bolts

Brakes:

Brake fluid level, Brake lines, Brake pads and disk thickness, Brake disks cleaning, Parking brake adjustment, Brake fluid replacement, Parking brake check

Electrical:

Warning and indicator lamps, Headlamp and exterior lamp inspection

Body Chassis:

Water leakage and corrosion inspection, Door hinges lubrication, Door locks lubrication, Hood lubrication, Sunroof cleaning, Soft top checking, Lower noise encapsulation removal/installation, Paint damage inspection, Water drains cleaning, Engine compartment lower panel removal/installation

Climate Control:

Cooling system, Heating system, AC refrigerant charge, Dust filter, Active charcoal filter, Recirculating air filter

Fuel System:

Fuel filter replacement, Fuel system condition check

Maintenance:

Engine oil and filter change, Valve clearance adjustment/checking, Idle speed adjustment, Injection timing adjustment, Fuel filter replacement, Air filter replacement, V-belt tension check, Coolant level/antifreeze check, Coolant replacement, Clutch disk wear check, Transmission oil change, Automatic transmission fluid/filter change, Transfer case fluid change, Clutch system fluid check, Steering fluid check, Battery fluid check, Windshield washer fluid check

Diagnostics Troubleshooting:

Component condition inspection, Lines and hoses inspection, Suspension and body structure inspection, Water leakage and corrosion inspection, Ball joint inspection (with special tool), Steering play check, Fuel system condition check, Brake system checks, Warning lamp checks

Repair Replacement:

Spark plug replacement, Oxygen sensor replacement, Air filter element replacement, Coolant replacement, Engine mount bolt re-torque, Fuel filter replacement, Brake fluid replacement, Wiper blade replacement

Lubrication:

Throttle linkage lubrication, Door hinges lubrication, Door locks lubrication, Sunroof rails lubrication, Folding side mirror lubrication, Hood lubrication

Depth:

Comprehensive Factory Level (Covers detailed repair, maintenance, diagnostics, adjustments, and specifications, mirroring dealer procedures)

📊 Manual Specifications

Format:

PDF

Searchability:

Fully searchable text

Bookmarking:

Completely bookmarked

Printability:

All pages are printable

Binding:

Not Applicable (Digital Download)

Paper:

Not Applicable (Digital Download)

Source:

Factory Original Files (Not scans)

⚙️ Engine Specifications

Engine Code:

OM601.912 (Common for 190 D 2.2)

Engine Type:

Inline 4-cylinder, Naturally Aspirated Diesel

Displacement:

2197 cc (2.2 Liters)

Horsepower:

Approx. 72-75 hp (at 4200-4400 rpm, depending on specific market/tuning)

Torque:

Approx. 107 lb-ft (at 2400-2600 rpm, depending on specific market/tuning)

Injection System:

Bosch inline injection pump (e.g., VE series)

Fuel Type:

Diesel Fuel

Valve Adjustment:

Mechanical adjustment via shims or screw-and-locknut (requires periodic checking and adjustment).

Timing Check:

Injection timing checked via specific tools (e.g., dial indicator or timing light/strobe on pulley).

🔧 Transmission

Type:

4-speed or 5-speed Manual Transmission

Type:

4-speed Automatic Transmission (e.g., 722.4)

Fluid Type Manual:

GL-4 Gear Oil (Specific viscosity, e.g., 75W-80 or 75W-90, check manual for exact specs).

Fluid Type Automatic:

Mercedes-Benz Automatic Transmission Fluid (ATF) - Often Dexron-II or equivalent, check manual for precise specification (e.g., MB-Approval 236.6).

📐 Dimensions

Length:

Approx. 4350-4420 mm (171.3-174.0 in)

Width:

Approx. 1680-1690 mm (66.1-66.5 in)

Height:

Approx. 1370-1420 mm (53.9-55.9 in)

Curb Weight:

Approx. 1200-1300 kg (2645-2866 lbs), varies by transmission and options

🛡️ Safety Features

Era Specific Safety:

Designed with advanced safety features for its time, including a robust chassis structure.

Seat Belts:

Front 3-point seat belts (likely with pre-tensioners in later models covered), rear lap belts or 3-point belts depending on specification.

Structure:

Reinforced safety cell, crumple zones.

💡 Technology Features

Audio System:

Factory-installed AM/FM radio with cassette player was common. Aftermarket upgrades are frequent.

ABS:

Anti-lock Braking System (ABS) was an optional feature on many W201 models, including the 190 D, during these years.

Connectivity Features:

Limited by era; primarily basic vehicle diagnostics and warning systems. No modern Bluetooth or infotainment connectivity.

🔧 Maintenance

Oil Change Interval:

Typically every 10,000 km or 6,000 miles, or annually (refer to specific manual recommendations).

Air Filter Replacement:

Every 20,000-30,000 km or annually (check manual for precise interval).

Fuel Filter Replacement:

Every 20,000-40,000 km or as recommended based on fuel quality.

Valve Adjustment Interval:

Typically every 40,000-60,000 km or as part of major servicing.

Engine Oil:

API CD or CE classification diesel engine oil, viscosity grade typically 10W-40 or 15W-40 (check manual for exact MB-approval).

Coolant:

Glycol-based antifreeze with corrosion inhibitors. Mercedes-Benz specifications for coolants should be followed (e.g., MB-Approval 325.0 or 325.2).

Diesel Specific:

Glow plug system reliability, injector wear, potential for vacuum leak issues affecting engine start/stop.

Chassis Specific:

Rust potential (especially around wheel arches, sills), worn suspension bushings, subframe mounts, and ball joints. Differential seals can also leak.

Electrical Common:

Aging wiring harnesses, dashboard warning lights, and some sensor failures are possible due to age.

📚 Vehicle History

Brand Focus:

Mercedes-Benz known for engineering excellence, luxury, and durability.

W201 Introduction:

Introduced in 1982 as the 'Baby Benz', filling a gap below the larger S-Class and E-Class models.

190 D Significance:

The 190 D model emphasized fuel economy and reliability, becoming a popular choice for long-distance drivers and taxi fleets.

Production Years:

1983-1993 (for W201 chassis, with specific engine variants covered by this manual from 1986-1989).

🏆 Awards & Recognition

Reliability Awards:

While specific awards for this model might not be widely published, Mercedes-Benz vehicles of this era are generally recognized for their long-term durability and build quality, often outperforming competitors in reliability surveys.