Vehicle Segment:
Compact Executive Sedan (often referred to as the 'Baby Benz')
Target Audience:
Individuals seeking reliable, comfortable, and well-built compact executive transport, often appreciating Mercedes-Benz engineering and durability.
Key Competitors:
BMW 3 Series (E30), Audi 80/90, Volvo 240, Alfa Romeo 75.
Manual Value Proposition:
Provides comprehensive, year-specific service and repair information for the 190 D 2.5 Diesel, enabling owners and mechanics to perform a wide range of maintenance and repairs with confidence.
Vehicle Key Features:
Known for its robust build quality, excellent ride comfort, and the reliable OM602 diesel engine. Introduced innovative safety features and pioneered a more compact executive sedan segment for Mercedes-Benz.
Engine Systems:
Fuel system (injection timing, filters, pre-filters), cooling system (coolant level, antifreeze, system checks), lubrication system (oil and filter change), valve train (clearance adjustment), air intake system, exhaust system, engine mounts.
Drivetrain Systems:
Manual transmission (oil change, level checks), automatic transmission (fluid and filter change, level checks), transfer case (fluid change, level checks), clutch system (fluid checks, inspection), drive shaft flexible coupling inspection.
Suspension Steering Brakes:
Suspension and body structure inspection, front axle (oil level, ball joint checks), rear axle (oil change, level checks, limiting stop adjustment), wheels (inspection, rotation, bolt tightening), tires (inspection, pressure correction), steering (play check, bolt retightening), brakes (fluid level, line inspection, pad/disk thickness, disk cleaning, parking brake adjustment/check, fluid replacement).
Electrical Systems:
Battery fluid level check, warning and indicator lamp checks, headlamp and exterior lamp inspection.
Comfort And Body:
Water leakage and corrosion inspection, lubricating door hinges and locks, hydraulic top fluid level, sunroof cleaning and greasing, soft top locking tab checks, windshield washer fluid level, windshield wiper blade replacement, AC refrigerant charge check, dust filter replacement (heating/ventilation, recirculating, active charcoal), lubricating folding side mirrors and hood, safety belt inspection, backrest lock operation, noise encapsulation panel removal/installation, body paint damage inspection.
Diagnostic Procedures:
Determining the cause of vehicle-related problems, inspecting component condition, lines, and hoses, checking valve clearance, checking and adjusting idle speed, checking and adjusting injection timing, checking fuel system condition.
Maintenance Procedures:
Engine oil and filter change, valve clearance adjustment, idle speed adjustment, injection timing adjustment, fuel filter replacement, fuel prefilter replacement, air filter cleaning/replacement, V-belt tension check, poly V-belt inspection, spark plug check/replacement, coolant level/antifreeze check, coolant replacement, engine stop adjustment, retorque engine mount bolts, transmission fluid/filter changes, clutch fluid checks, throttle linkage lubrication, wheel inspection/rotation, tire pressure correction, brake fluid checks/replacement, parking brake adjustment, steering bolt retightening, exhaust flange/system connections retightening, battery fluid level checks, water drain cleaning, door hinge/lock lubrication, sunroof lubrication, wiper blade replacement, cabin filter replacement.
Repair Procedures:
Disassembly, inspecting parts for reuse, rebuilding and assembly of components, replacement of various parts including oxygen sensor, brake pads/disks, clutch disk, windshield wiper blades, filters, etc.
Depth Of Coverage:
Comprehensive; covers detailed inspection, diagnosis, maintenance, and repair procedures for all major vehicle systems. Intended for both professional mechanics and skilled DIY enthusiasts.
Engine Type:
Inline-5 Cylinder Diesel
Displacement:
2.5 Liters (2497 cc)
Engine Code:
OM602.911 (Typical for 190 D 2.5)
Horsepower:
Approximately 90 HP (67 kW) at 4600 rpm
Torque:
Approximately 150 lb-ft (203 Nm) at 2800 rpm
Fuel Delivery:
Bosch Inline Injection Pump (typically VE type) with mechanical injectors.
Maintenance Considerations
Valve Adjustment:
Requires periodic adjustment of valve clearances, typically via shims, as detailed in the manual.
Injection Timing:
Critical for performance and emissions; requires specific tools and procedures for adjustment.
Oil Change Interval:
Typically every 3,000-5,000 miles (5,000-8,000 km) or annually, depending on driving conditions. The manual will provide specific recommendations.
Fuel Filter Replacement:
Recommended every 15,000-30,000 miles (24,000-48,000 km) or as indicated by performance issues. The manual details this procedure.
Air Filter Replacement:
Recommended every 15,000-30,000 miles (24,000-48,000 km) or as needed based on inspection. Manual covers cleaning metal reinforced elements and replacing standard elements.
Engine Oil Specification:
API CD or CE classification for diesel engines, viscosity typically 15W-40 or 10W-40 depending on climate. Manual will confirm exact MB specifications.
Coolant Specification:
Ethylene glycol-based antifreeze/coolant meeting MB Specification 325.0 or 326.0 (green or blue coolant). Manual will detail mixture ratios.
Common Wear Items:
V-belts, suspension bushings, ball joints, vacuum lines (prone to cracking), exhaust system components, glow plugs.
Diesel Specific Concerns:
Injection pump seals, injector performance, potential for carbon buildup in intake ports, proper pre-heating for cold starts.
Mercedes Benz Legacy:
Mercedes-Benz has a long-standing reputation for engineering excellence, durability, and luxury, dating back to the invention of the automobile.
W201 Introduction:
The W201 chassis was introduced in 1982 as a more compact and accessible entry-level Mercedes-Benz, challenging the status quo of larger, more expensive models.
190 D 2.5 Significance:
The 190 D 2.5 represented a significant diesel offering in the W201 lineup, providing a balance of fuel economy and Mercedes-Benz reliability. The OM602 engine became a workhorse for the brand.
Production Period:
The W201 chassis was produced from 1982 to 1993. The 190 D 2.5 variant was available within this period, with specific model years covered by this manual being 1986-1989.
