🏷️ Basic Information

Make:

Mercedes-Benz

Model:

190 D Turbo

Year:

1987

Chassis Code:

W201

Engine Code:

OM602.911

👋 Introduction

Segment:

Compact Executive Sedan (often referred to as the 'Baby Benz')

Target Audience:

Owners and independent repair shops seeking comprehensive, factory-accurate service information for the W201 platform, specifically the 190 D 2.5 Turbo variant.

Competitors 1987:

BMW 3 Series (E30), Audi 80/90, Volvo 240, smaller luxury sedans from Cadillac, Lincoln.

Durability:

The W201 platform is renowned for its robust build quality and long-term durability, especially with the OM602 diesel engine.

Diesel Performance:

The 'Turbo' designation signifies a significant performance upgrade over naturally aspirated diesel models, offering improved acceleration and drivability.

Usefulness:

Provides owner-level DIY capabilities for maintenance and minor repairs, as well as in-depth technical data for professional mechanics.

Convenience:

Instant digital download format allows immediate access, eliminating shipping delays and costs.

📋 Manual Details

Primary Focus:

Service and Repair

Covered Variants:

190 D 2.5 Turbo

Estimated Pages:

Variable (as it's a download, page count not specified but implied to be comprehensive)

Type:

Factory Service and Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine:

2.5L 5-cylinder Turbo Diesel (OM602.911), including inspection, oil/filter changes, valve adjustments, idle speed, injection timing, fuel system, air intake, V-belts, exhaust manifold, spark plugs (though diesel, manual may cover glow plugs), cooling system.

Transmission:

Manual and Automatic transmission fluid changes, level checks, and adjustments. Clutch system inspection and fluid correction.

Drivetrain:

Transfer case fluid change and level check, front and rear axle oil changes and level checks. Drive shaft flexible coupling inspection.

Brakes:

Brake fluid level and line inspection, brake pads and disk thickness checks, brake disk cleaning, parking brake adjustment and cable inspection, brake fluid replacement, brake testing.

Suspension Steering:

Suspension and body structure inspection, level control (ADS), 4MATIC fluid level, self-leveling suspension inspection, ball joint inspection, steering play check, steering bolt tightening.

Electrical:

Warning and indicator lamp checks, headlamp and exterior lamp inspection, windshield wiper and washer inspection, antenna mast cleaning, battery fluid level check.

Body Chassis:

Body structure inspection, water leakage and corrosion inspection, lower engine compartment panel removal/installation, door hinge/lock lubrication, sunroof rail cleaning/greasing, soft top checking, hood lubrication, lower noise encapsulation panel removal/installation, paint damage inspection.

Climate Control:

Dust filter, active charcoal filter, and recirculating air filter replacement. AC refrigerant charge check and correction. Windshield washer fluid level check.

Maintenance:

Routine maintenance tasks such as fluid changes (engine oil, transmission oil, axle oil, power steering fluid, hydraulic fluid), filter replacements (oil, fuel, air, dust, charcoal), belt tension checks, and lubrication.

Diagnostics:

Component condition inspection, line and hose inspection, leak checks, corrosion checks, electrical system checks (warning lamps), and general system diagnostics.

Adjustments:

Valve clearance adjustment, idle speed adjustment, injection timing adjustment, parking brake adjustment, engine mount bolt re-torquing, engine stop adjustment.

Replacements:

Engine oil filter, fuel filter, air filter element, spark plugs, oxygen sensor, coolant, transmission fluid and filter, brake fluid, wiper blades.

Inspections:

Comprehensive visual and functional inspections of all major vehicle systems, including suspension, steering, brakes, drivetrain, engine components, bodywork, and safety features.

Depth:

Factory-level detail, equivalent to what authorized Mercedes-Benz dealerships use. Covers routine maintenance to detailed repair procedures.

📊 Manual Specifications

Type:

PDF

Searchability:

Fully searchable text

Quality:

High-quality, suitable for printing individual pages or sections.

Type:

Digital Download (No physical binding)

Type:

N/A (Digital)

Delivery:

Instant Download

Source:

Factory Service Manuals (claimed to be 'real files not scans')

⚙️ Engine Specifications

Engine Type:

Inline 5-cylinder, Turbocharged Diesel

Displacement:

2497 cc (2.5 Liters)

Bore X Stroke:

87.0 mm x 84.0 mm

Compression Ratio:

22.0:1

Horsepower:

Approx. 126 PS (124 hp; 93 kW) at 4600 rpm (depending on specific market tune)

Torque:

Approx. 230 Nm (170 lb-ft) at 2400 rpm (depending on specific market tune)

Injection System:

Bosch VE Rotary Injection Pump (Mechanical)

Type:

Garrett AiResearch or similar (specific model may vary)

Coolant Capacity:

Approx. 8.5 Liters (check manual for exact specification)

Valve Adjustment Type:

Mechanical, via shims (requires feeler gauges and knowledge of clearances)

🔧 Transmission

Type:

4-Speed Manual (common), 5-Speed Manual (optional/later models)

Type:

4-Speed Automatic (722.4 variant common)

Manual Oil Type:

MB 235.4 (e.g., Pentosin, Castrol SAF-XO - check manual for specific MB spec)

Automatic Fluid Type:

MB 236.6 (e.g., MB AT Fluid LT2 or equivalent Dexron II/III)

Clutch Type:

Hydraulically actuated diaphragm spring clutch

📐 Dimensions

Length:

Approx. 4420 mm (174.0 in)

Width:

Approx. 1690 mm (66.5 in)

Height:

Approx. 1390 mm (54.7 in)

Curb Weight:

Approx. 1300-1400 kg (2866-3086 lbs) depending on transmission and options

Wheelbase:

Approx. 2665 mm (104.9 in)

Standard Tire Size:

195/65 R15 (common for this model)

Bolt Pattern:

5x112

Center Bore:

66.6 mm

🛡️ Safety Features

Crash Test Data:

While specific 'ratings' like modern NCAP may not exist, the W201 was designed with significant safety advancements for its era, including a robust crumple zone and safety cell. (Refer to the manual for specific chassis integrity checks).

ABS:

Anti-lock Braking System (ABS) was an optional feature on many W201 models.

Seatbelts:

Front seatbelt pre-tensioners, rear seat belts. Manual covers inspection and operation.

Body Structure:

High-strength steel body, reinforced A and B pillars, safety steering column. Manual covers inspection of structural integrity.

💡 Technology Features

Audio System:

Factory-installed Becker or Blaupunkt radio/cassette systems were common. Manual covers cleaning of components like the tone head.

Level Control Ads:

Optional Automatic Differential Suspension (ADS) system, which adjusted suspension damping. Manual covers fluid levels and inspection.

4Matic:

4MATIC all-wheel-drive system was also an option, requiring specific maintenance for its drivetrain components. Manual covers transfer case and axle fluid checks.

Headlamps:

Halogen headlamps. Manual covers inspection and replacement procedures.

🔧 Maintenance

Engine Oil Change:

Typically every 5,000-10,000 km (3,000-6,000 miles) or annually, depending on driving conditions. (Refer to manual for exact interval and type of oil).

Fuel Filter Replacement:

Typically every 20,000-40,000 km (12,000-25,000 miles). The manual details the process for this common maintenance item.

Air Filter Replacement:

Recommended inspection at oil changes, replacement every 20,000-40,000 km (12,000-25,000 miles).

Engine Oil Specification:

API CD or higher, SAE 15W-40 or 10W-40 recommended (check manual for specific MB approval). Diesel engine oil formulation is crucial.

Coolant Specification:

Ethylene glycol-based coolant (e.g., MB 325.0 or equivalent) with appropriate antifreeze protection. Manual specifies ratio.

Diesel Specific:

Glow plug system reliability, injector seal leaks, vacuum leak issues affecting performance, fuel heater failures in cold climates. Manual covers testing and replacement.

General W201:

Corrosion (especially in wheel arches and sills), headliner sagging, HVAC system issues, and potential for the self-leveling suspension (if equipped) to fail. Manual covers inspections and repairs.

📚 Vehicle History

Mercedes Benz Philosophy:

Reputation for engineering excellence, durability, and luxury.

W201 Introduction:

Introduced in 1982 as the first compact Mercedes-Benz, designed to be more accessible than larger S-Class models while retaining core Mercedes-Benz values.

Diesel Development:

The OM602 engine series was a significant development in Mercedes diesel technology, offering increased power and refinement over previous generations.

Production Years:

1982-1993 (for W201 platform); 2.5 Turbo diesel variant introduced later in the production cycle.

Manufacturing Location:

Bremen, Germany (primary plant)

🏆 Awards & Recognition

Automotive Press 1980S:

The W201 received acclaim for its build quality, driving dynamics, and safety innovations, often praised by automotive journalists of the era.

Consumer Reputation:

The 190 D models, particularly the turbocharged variants, built a reputation for longevity and reliability when properly maintained, a testament to Mercedes-Benz engineering.