Vehicle Segment:
Compact Executive Sedan ('Baby Benz')
Target Audience:
Owners seeking to maintain, repair, or restore their W201 190 D, including DIY enthusiasts and independent mechanics.
Key Competitors Era:
BMW E30 3 Series, Audi 80/90, Volvo 240 series
Manual Advantage:
Provides the same level of detail as used by professional technicians, empowering owners with confidence for repairs.
Content Scope:
Extensive coverage of diagnostics, maintenance, repair, and refurbishment procedures.
Engine Mechanical:
Engine diagnostics, overhaul, valve adjustments, timing, fuel injection system (Bosch VE),
Cooling System:
Coolant checks, replacement, radiator, thermostat, water pump, heater core
Fuel System:
Fuel filter replacement, pre-filter, fuel lines, injection pump testing and adjustment
Air Intake Exhaust:
Air filter maintenance, intake manifold, exhaust system diagnostics and repair
Transmission Drivetrain:
Manual and Automatic transmission fluid changes, level checks, clutch system service, drive shaft coupling
Suspension Steering:
Front and rear axle inspection, ball joint checks, oil level checks, wheel alignment basics, steering play
Brakes:
Brake fluid checks, replacement, pad and disc inspection, brake line inspection, parking brake adjustment
Electrical System:
Wiring schematics, lighting inspection, battery checks, warning lamps
Body Chassis:
Body structure inspection, water leakage, corrosion checks, lubrication of hinges and locks, paint damage inspection
Comfort Convenience:
HVAC system, AC refrigerant checks, dust/charcoal filter replacement, sunroof lubrication, hydraulic top systems
Routine Maintenance:
Oil and filter changes, air filter replacement, fuel filter replacement, fluid level checks, V-belt inspection
Troubleshooting:
Diagnostic procedures for common issues, fault finding across all major systems
Repair Rebuild:
Step-by-step instructions for component removal, installation, and overhaul
Adjustments:
Valve clearance, idle speed, injection timing, parking brake, steering bolts
Inspections:
Detailed inspection checklists for components, lines, hoses, suspension, body, brakes, tires, and safety belts
Depth Of Coverage:
Comprehensive. Covers basic maintenance to detailed engine, transmission, and electrical system repairs.
Diagnostic Information:
Includes procedures for diagnosing common faults and performance issues specific to the OM601 engine.
Diagrams Illustrations:
Step-by-step instructions supplemented with diagrams, illustrations, and wiring schematics for clarity.
Digital File Types:
PDF (Portable Document Format), WINRAR (Compressed Archive)
Readability:
Designed for clear viewing on screens and printing. High-resolution diagrams and text.
Digital Format Advantage:
Instant download, accessible across multiple devices and operating systems.
Digital Format Usability:
Printable pages for physical reference in a workshop environment.
Standard Transmission Type:
4-speed Manual Transmission (early models)
Optional Transmission Type:
4-speed Automatic Transmission (often designated 722.4)
Transmission Fluid Type:
Refer to manual for specific MB specification (e.g., MB 236.2 for manual, MB 236.7 for early automatics)
Oil Change Interval:
Typically 7,500-10,000 miles or annually (consult manual for exact specification).
Air Filter Replacement Interval:
Every 15,000-30,000 miles or as needed based on operating conditions (consult manual).
Fuel Filter Replacement Interval:
Every 20,000-40,000 miles or annually (consult manual).
Engine Oil Specification:
API CD or CE classification, viscosity grade typically 10W-40 or 15W-40 Diesel oil (refer to manual for exact MB approval).
Coolant Specification:
Mercedes-Benz approved anti-freeze/anti-corrosion concentrate (e.g., G48 or equivalent) mixed with distilled water.
Brake Fluid Specification:
DOT 3 or DOT 4 glycol-based brake fluid (consult manual for exact specification).
Common Wear Items:
V-belts, glow plugs, fuel injectors, vacuum lines, suspension bushings, and potential for rust in typical areas.
Diesel Specific Concerns:
Injection pump timing, injector seal leaks, and proper functioning of the pre-heater system.
Mercedes Benz Legacy:
Continued Mercedes-Benz's reputation for build quality, durability, and engineering excellence.
W201 Introduction:
Launched in 1982, the W201 was Mercedes-Benz's entry into the compact executive car segment.
190D Significance:
The 190 Diesel model was renowned for its exceptional fuel economy and longevity, becoming a popular choice for high-mileage drivers.
Production Period:
1982-1993 (W201 chassis overall); this manual covers 1984-1986 models.
