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Mercedes 190 E 2.6 1987-1993 Service Repair Manual

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: 190 E 2.6 Chassis Code: W201 Codes Engine Code: M103.983 Body Style: Sedan 👋 Introduction Market Position Segment: Compact Executive Sedan Era: Late...
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Mercedes 190 E 2.6 1987-1993 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mercedes-Benz
Model:
190 E 2.6
Chassis Code:
W201
Codes
Engine Code:
M103.983
Body Style:
Sedan
👋 Introduction
Market Position
Segment:
Compact Executive Sedan
Era:
Late 1980s to early 1990s luxury automotive segment
Competitive Analysis
Competitors:
BMW 3 Series (E30), Audi 80/90, Saab 900, Volvo 240/740
Key Features
Engineering Philosophy:
Mercedes-Benz build quality, safety, and engineering prowess in a more compact and accessible package than the E-Class or S-Class.
Popularity:
Known for its robust construction, comfortable ride, and longevity, often referred to as the "Baby Benz".
📋 Manual Details
Coverage
Applicable Years:
1987, 1988, 1989, 1990, 1991, 1992, 1993
Engine Coverage:
2.6L M103 Inline-6 Engine
Format
Format:
PDF Download
Delivery:
Instant Download
Language
Language:
English
Manual Type
Type:
Factory Service & Repair Manual
Page Count
Estimated Page Count:
Extensive (Factory Manual Scope)
Searchability
Searchable:
Yes (Fully Bookmarked & Searchable)
Print Quality
Printability:
Yes (All pages printable)
Authenticity
Source:
OEM Factory Files (Not scans)
📖 Manual Coverage
Systems Covered
Engine:
Engine mechanicals, lubrication, cooling, fuel injection (KE-Jetronic), ignition, exhaust, engine mounts, emission controls
Transmission:
Manual transmission (4 & 5 speed), Automatic transmission (4 speed 722.4), clutch system, driveline
Brakes:
Hydraulic system, calipers, pads, rotors, parking brake, ABS (if equipped)
Suspension:
Front and rear suspension, struts, shock absorbers, springs, control arms, ball joints, bushings, leveling control (ADS - optional)
Steering:
Power steering system, steering gear, tie rods, steering column
Electrical:
12V system, battery, charging system, starter, lighting (headlamps, exterior, interior), indicators, warning lamps, horn, wiper/washer system, fuse/relay box
Body And Chassis:
Body structure, corrosion inspection, water leaks, door hinges, locks, hood, sunroof, soft top mechanism (if applicable), windshield wipers/washers, body panels, noise encapsulation
HVAC:
Heating and ventilation system, AC refrigerant charge, dust filter, recirculating air filter, active charcoal filter
Procedures Included
Maintenance:
Oil and filter changes, fluid level checks and top-offs, belt inspections and tensioning, air filter replacement, spark plug replacement, fuel filter replacement, coolant replacement, valve clearance adjustment
Diagnostics:
Troubleshooting common issues, diagnosing engine performance problems, identifying electrical faults, brake system diagnostics
Repairs:
Engine component replacement (e.g., oxygen sensor, manifold gaskets), transmission fluid and filter changes, brake pad and rotor replacement, suspension component replacement (ball joints, bushings), clutch system servicing, power steering system repairs
Adjustments:
Idle speed adjustment, injection timing adjustment, parking brake adjustment, steering bolt tightening, wheel bolt tightening
Technical Depth
Depth:
Comprehensive from basic maintenance to major component repair and overhaul, including torque specifications, diagnostic procedures, and wiring diagrams (typically within factory manuals).
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Quality:
High-resolution, professional quality, suitable for printing
Binding Type
Binding:
Digital (No physical binding)
Paper Type
Paper:
Digital (Not applicable)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 6-cylinder, SOHC
Displacement:
2599 cc (2.6 Liters)
Bore X Stroke:
82.5 mm x 76.7 mm
Compression Ratio:
9.2:1
Performance
Horsepower:
160 hp (approx. @ 5500 rpm)
Torque:
228 Nm (168 lb-ft) (approx. @ 3000 rpm)
Fuel System
Fuel Injection:
Bosch KE-Jetronic Mechanical/Electronic Fuel Injection
Fuel Type:
Unleaded Gasoline (Octane rating typically 91 RON/87 AKI or higher)
Engine Management
Ignition System:
Electronic Ignition with Distributor
Emission Control:
Catalytic Converter, Lambda (Oxygen) Sensor
🔧 Transmission
Standard
Type:
4-Speed Automatic (722.4)
Optional
Type:
5-Speed Manual (Getrag 260/5)
Features
Automatic Features:
Torque converter, hydraulic control
Fluid Specifications
Automatic Fluid Type:
MB 236.1 (e.g., Mobil ATF 220, Pentosin ATF-1)
Manual Fluid Type:
MB 235.1 (e.g., SAE 80W/90 GL-4)
📐 Dimensions
Exterior
Length:
4420 mm (174 in)
Width:
1690 mm (66.5 in)
Height:
1390 mm (54.7 in)
Wheelbase:
2665 mm (104.9 in)
Weights
Curb Weight:
1350-1450 kg (2976-3197 lbs) (approx., varies by transmission and equipment)
Gross Vehicle Weight Rating:
1850 kg (approx.)
Wheels And Tires
Wheel Bolt Pattern:
5x112 mm
Standard Tire Size:
195/65 HR 15
Standard Wheel Size:
15 x 6.0J
🛡️ Safety Features
Ratings
Era Standard Safety:
Designed to high Mercedes-Benz standards for its time, including crumple zones, safety cage, and energy-absorbing steering column.
Active Features
ABS:
Anti-lock Braking System (ABS) available as an option on later models.
Passive Features
Airbags:
Driver airbag standard on later models, passenger airbag optional.
Seatbelts:
Front and rear seat belts, pre-tensioners (on later models).
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM radio with cassette player, optional CD changer available on later models.
Driver Assistance
Cruise Control:
Available as an option.
Climate Control
HVAC System:
Manual climate control standard, optional automatic climate control (Klima-Automatik) on some models.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 7,500-10,000 miles or 12-18 months (refer to manual for precise intervals based on driving conditions).
Air Filter Replacement:
Every 15,000-30,000 miles or as needed based on dusty conditions.
Spark Plug Replacement:
Typically 30,000-60,000 miles (depending on plug type, e.g., standard vs. long-life).
Coolant Replacement:
Every 2-3 years or as specified by coolant manufacturer.
Fluid Specifications
Engine Oil Specification:
MB 229.1 or API SG/SH, SAE 10W-30 or 10W-40 (depending on climate, refer to manual).
Brake Fluid Specification:
DOT 3 or DOT 4.
Power Steering Fluid Specification:
MB 236.3 (e.g., Pentosin CHF 11 S or equivalent hydraulic fluid).
Known Issues
Common Problems:
Head gasket leaks, fuel distributor issues (KE-Jetronic), vacuum hose degradation, front suspension wear (ball joints, bushings), blower motor failure, OVP relay failure (for EFI models).
Common Tasks
Valve Adjustment:
Requires periodic checking and adjustment of valve clearances as per factory procedure.
📚 Vehicle History
Brand Heritage
Brand:
Mercedes-Benz, established in 1926, renowned for luxury, engineering, and pioneering automotive safety.
Model Evolution
Introduction Year:
1982 (W201 platform)
190E 2.6 Introduction:
Introduced in 1986 for the 1987 model year, offering a significant upgrade in power and refinement over the 4-cylinder models.
Production
Production Period:
1982-1993 (W201 platform)
Manufacturing Location:
Sindelfingen, Germany
🏆 Awards & Recognition
Recognitions
Safety Awards:
Consistently rated highly for safety and build quality within its class during its production run.
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