🏷️ Basic Information

Make:

Mercedes-Benz

Model:

190 D Turbo

Year:

1987

Chassis Code:

W201

Engine Code:

OM602.911

Generation:

First Generation (W201)

👋 Introduction

Market Position:

The Mercedes-Benz W201, particularly the 190 D Turbo, represented Mercedes-Benz's entry into the compact executive car segment. It was designed to offer Mercedes-Benz quality and engineering in a more accessible package, competing with models like the BMW 3 Series. The 'D' designation signifies a diesel engine, and the 'Turbo' highlights its turbocharged nature, offering improved performance for a diesel of its era.

Competitive Analysis:

The W201 was praised for its build quality, sophisticated multilink rear suspension, and robust engineering. It established Mercedes-Benz as a player in the smaller luxury car market, challenging established competitors with its blend of comfort, durability, and performance, especially with the efficient and torquey turbodiesel engine.

Key Features:

Robust OM602 turbodiesel engine, sophisticated multilink rear suspension, high build quality, advanced safety features for its time (e.g., optional ABS, ASD), comfortable and driver-focused interior, excellent fuel economy for its performance.

📋 Manual Details

Coverage Areas:

Engine, Fuel System, Cooling System, Lubrication System, Exhaust System, Clutch, Transmission (Manual & Automatic), Drive Shaft, Axles, Suspension (Front & Rear), Steering, Brakes, Electrical System, Body, Heating & Ventilation, Air Conditioning

Page Count:

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

Manual Type:

Factory Service Repair Manual

Language:

English

Format:

PDF / WINRAR

📖 Manual Coverage

Systems Covered:

Engine mechanical, engine electrical, fuel injection (Bosch VE), turbocharger, cooling, lubrication, exhaust, clutch, manual transmission, automatic transmission (e.g., 722.4), driveline, front suspension, rear suspension (multi-link), steering, hydraulic leveling control (optional), anti-slip regulation (ASD, optional), four-wheel drive (4MATIC, optional), brakes (hydraulic, ABS, parking), electrical system (wiring diagrams, components), body structure, interior trim, HVAC, safety systems (seat belts, airbags - if equipped)

Body Structure Inspection:

Includes procedures for inspecting for water leaks, corrosion, and overall body integrity.

Level Control Ads Asd 4Matic:

Covers fluid level checks and related maintenance for optional advanced suspension and drive systems.

Parking Brake Adjustment:

Detailed instructions for adjusting the parking brake for proper engagement and holding power.

HVAC Filter Replacement:

Includes replacement procedures for dust filters and active charcoal filters in the heating and ventilation system.

V Belt Inspection:

Procedures for checking the condition and tension of V-belts and Poly V-belts.

Chassis And Suspension:

Detailed coverage of front and rear axles, ball joint inspection, and wheel alignment checks.

Brake System Checks:

Comprehensive checks including brake fluid level, brake lines, pad and disc thickness, and parking brake function.

Steering System Checks:

Includes checking steering play, retightening steering bolts, and checking power steering fluid level.

Electrical And Lighting:

Inspection of warning lamps, indicator lamps, headlamps, and exterior lamps.

Engine Oil And Filter Change:

Step-by-step guide for performing routine engine oil and filter changes, including capacity and correct fluid type.

Injection Timing:

Procedures for checking and adjusting the injection timing of the diesel fuel system, vital for performance and emissions.

Cooling And Heating System:

Covers checking coolant level, antifreeze protection, and the process of replacing coolant.

Procedures Included:

Disassembly, inspection, cleaning, rebuilding, assembly, adjustments, diagnostics, troubleshooting, replacement of all major and minor components, fluid level checks and changes, filter replacements, belt adjustments, spark plug checks/replacement, valve clearance adjustment, injection timing, brake bleeding, electrical component testing, bodywork repair guidance, AC service (refrigerant charge, filter replacement)

Throttle Linkage Lubrication:

Details on how to properly lubricate and inspect the throttle linkage for smooth operation.

Wheel Bolt Tightening:

Provides correct torque specifications for wheel bolt tightening to ensure safety and prevent damage.

Exhaust System Connections:

Guidance on checking and tightening exhaust system connections to prevent leaks and noise.

Wiper Washer Inspection:

Covers inspection and replacement of windshield wiper blades and checking the washer system functionality.

Engine Mount Retorquing:

Instructions for adjusting the engine stop and retorquing engine mount bolts for proper engine alignment and vibration isolation.

Drive Shaft Coupling Inspection:

Guidance on inspecting the condition and integrity of the drive shaft flexible coupling.

Hydraulic Top Fluid Level:

For convertible models, this manual would likely cover checking and correcting the fluid level for the hydraulic convertible top system.

Fuel System Condition Check:

Procedures for inspecting the overall condition of the fuel system, including lines and filter.

Battery Fluid Level Check:

Instructions for checking the electrolyte level in conventional lead-acid batteries, if applicable to the specific 1987 model.

Valve Clearance Adjustment:

Detailed instructions for checking and adjusting valve clearances, a critical maintenance item for diesel engines.

Air Filter Replacement:

Includes cleaning metal-reinforced elements and replacing standard air filter elements.

Technical Depth:

Comprehensive, covering everything from routine maintenance and fluid changes to detailed engine rebuilds, transmission overhauls, and complex electrical system diagnostics. Includes torque specifications, clearances, special tool usage, and diagnostic flowcharts.

📊 Manual Specifications

File Format:

PDF files contained within a WINRAR archive. PDF quality is typically high-resolution scans of original factory manuals, ensuring clarity of diagrams and text.

Print Quality:

High quality, suitable for printing. Diagrams are clear, and text is legible.

Binding Type:

Digital (PDF/WINRAR). For printed versions, expect a professional comb or perfect binding.

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine:

2.5L Inline 5-Cylinder Turbocharged Diesel (OM602.911)

Horsepower:

Approximately 126 hp @ 4600 rpm

Torque:

Approximately 195 lb-ft (265 Nm) @ 2400 rpm

Fuel System:

Bosch VE (VP) mechanical injection pump with turbocharger and intercooler.

Bore Stroke:

87.0 mm x 84.0 mm

Compression Ratio:

21.0:1

Cooling System Capacity:

Approximately 8.5 liters (coolant mixture)

🔧 Transmission

Standard Transmission:

5-speed Manual Transmission

Optional Transmission:

4-speed Automatic Transmission (722.4)

Transmission Features:

Both transmissions are robust. The automatic offers smooth shifts and torque converter lock-up for improved efficiency. Manual transmission fluid type is typically MB 235.0 or equivalent.

📐 Dimensions

Length:

Approximately 4420 mm (174 in)

Width:

Approximately 1690 mm (66.5 in)

Height:

Approximately 1380 mm (54.3 in)

Curb Weight:

Approximately 1350-1450 kg (2976-3197 lbs), depending on equipment.

Gross Vehicle Weight:

Approximately 1850 kg (4079 lbs)

🛡️ Safety Features

Safety Ratings:

While formal crash test ratings like Euro NCAP or NHTSA were less standardized in 1987, the W201 was engineered with a strong safety cell, crumple zones, and a focus on occupant protection. It was considered a very safe vehicle for its time.

Active Features:

Optional Anti-lock Braking System (ABS), Optional Anti-Slip Regulation (ASD).

Passive Features:

Reinforced body structure, energy-absorbing steering column, driver's side airbag (optional on later models), pre-tensioned seat belts, impact-resistant door beams.

💡 Technology Features

Infotainment Features:

Basic analog radio systems, cassette players. Analog climate controls for heating and ventilation. Optional air conditioning.

Driver Assistance Features:

Optional ABS and ASD provided advanced traction and braking control for the era. Cruise control was also available on some models.

Connectivity Features:

N/A (No modern digital connectivity features such as Bluetooth or USB). Antenna mast for radio reception.

🔧 Maintenance

Service Intervals:

Oil Change: Every 7,500-10,000 miles (12,000-16,000 km) or 12 months. Fuel Filter: Every 15,000-20,000 miles (24,000-32,000 km). Air Filter: Every 15,000-20,000 miles (24,000-32,000 km). Coolant: Every 2-3 years or 30,000-50,000 miles (50,000-80,000 km). Valve Adjustment: As per manual recommendations, typically every 30,000-50,000 miles (50,000-80,000 km).

Engine Oil Specification:

API CD/CE or higher, SAE 10W-40 or 15W-40 (depending on climate). Consult manual for precise Mercedes-Benz approval (e.g., MB 228.1).

Coolant Specification:

Mercedes-Benz Approved Antifreeze/Coolant (e.g., G48). Typically a 50/50 mix with distilled water.

Transmission Oil Manual:

MB 235.0 or equivalent SAE 75W-80/85W-90 gear oil.

Transmission Oil Automatic:

MB 236.7 or equivalent Dexron II (or later compatible). Capacity approx. 7.5 liters for change with filter.

Brake Fluid Specification:

DOT 3 or DOT 4.

Power Steering Fluid:

MB 236.3 or equivalent ATF (Dexron II).

Known Issues:

Potential for rust in common areas (wheel arches, sills, jacking points). Glow plug system issues. Injector pump wear. Overheating if cooling system maintenance is neglected. Vacuum line leaks affecting various systems. Differential seal leaks. Subframe mount wear. Transmission mount deterioration. Suspension component wear (bushings, ball joints).

Oil Filter Part Number:

Commonly Mann-Filter W102/2, Mahle OX11D, Bosch 0 451 103 013 (verify for specific vehicle)

Fuel Filter Part Number:

Commonly Mann-Filter WK80, Bosch 0 450 504 525 (verify for specific vehicle)

Air Filter Part Number:

Commonly Mann-Filter C2022/1, Mahle LX561 (verify for specific vehicle)

📚 Vehicle History

Brand Heritage:

Mercedes-Benz has a long-standing reputation for engineering excellence, luxury, and durability, dating back to the invention of the automobile.

Model Evolution:

The W201, often referred to as the 'Baby Benz', was a groundbreaking model for Mercedes-Benz, launched in 1982. It aimed to capture a younger demographic and provide a more compact, agile Mercedes. The 190 D Turbo variant, introduced later, offered a significant performance boost over naturally aspirated diesel models, making it more practical for highway driving and faster acceleration.

Production Years:

1982-1993 (W201 platform). The 190 D Turbo 2.5 was available from the mid-1980s, with the 1987 model year being a key representative of this variant.

Manufacturing Locations:

Primarily manufactured in Germany (e.g., Bremen plant).

🏆 Awards & Recognition

Recognitions:

The W201 platform generally received critical acclaim for its engineering, durability, and driving dynamics, solidifying Mercedes-Benz's reputation in the compact luxury segment. It was often praised for its build quality that surpassed many competitors.