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Mercedes 190E 2.6 1986-1993 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: 190E 2.6 Chassis Code: W201 Model Years Covered: 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993 Codes Engine Code: M103.942 👋 Introduction Market...
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厂商:
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Mercedes 190E 2.6 1986-1993 Workshop Repair Service Manual
🏷️ Basic Information
Identification
Make:
Mercedes-Benz
Model:
190E 2.6
Chassis Code:
W201
Model Years Covered:
1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993
Codes
Engine Code:
M103.942
👋 Introduction
Market Position
Segment:
Compact Executive Sedan
Brand Perception:
Luxury, Engineering Excellence, Durability
Competitive Analysis
Key Competitors:
BMW 3 Series (E30), Audi 80/90, Volvo 240/740, Lexus ES 250
Key Features
Design Philosophy:
Bauhaus-inspired, functional and robust design
Powertrain Emphasis:
Smooth inline-six power delivery, renowned Mercedes-Benz reliability
Manual Value Proposition
Benefit:
Empowers owners and technicians to perform accurate maintenance and repairs, preserving vehicle value and performance.
📋 Manual Details
Coverage Areas
Primary Coverage:
Workshop Repair and Service
Page Count
Estimated Page Count:
500+
Manual Type
Type:
Comprehensive Workshop Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, Fuel System, Ignition System, Exhaust System, Cooling System, Lubrication System, Automatic Transmission
Chassis:
Suspension (Front & Rear), Steering System, Braking System (Front & Rear), Wheels & Tires
Electrical:
Engine Control Unit (ECU), Ignition System, Lighting System, Instrumentation, Wiper/Washer System, Power Accessories (Windows, Locks, Mirrors), Audio System, Climate Control Electricals
Body And Interior:
Body Panels, Doors, Hood, Trunk Lid, Bumpers, Seats, Interior Trim, HVAC System (Mechanical Components)
Procedures Included
Maintenance:
Routine Service, Fluid Changes, Filter Replacements, Lubrication Points
Diagnostics:
Troubleshooting Guides, Symptom-Based Diagnostics, Component Testing Procedures
Repair:
Component Removal & Installation, Overhaul Procedures, Adjustments
Specifications:
Torque Specifications, Clearances, Tolerances, Electrical Values
Technical Depth
Depth:
Comprehensive, from basic maintenance to advanced diagnostics and full rebuilds
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Text-searchable
Print Quality
Quality:
High-resolution, suitable for printing
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 6-cylinder, SOHC
Displacement:
2.6 Liters (2599 cc)
Performance
Horsepower:
160 hp @ 5700 rpm (approx.)
Torque:
177 lb-ft @ 4400 rpm (approx.)
Fuel System
Injection Type:
Bosch KE-Jetronic Fuel Injection (or similar mechanical/electronic hybrid)
Fuel Type:
Premium Unleaded Gasoline (91 octane or higher recommended)
Cooling System
Coolant Type:
Mercedes-Benz approved coolant (e.g., G05 or equivalent) mixed with distilled water
Lubrication System
Oil Capacity:
7.5 Liters (with filter) (approx.)
Recommended Oil Viscosity:
SAE 15W-40 or 10W-40 (depending on climate, consult manual for exact MB specs)
Engine Management
Ignition System:
Electronic Ignition with Distributor
🔧 Transmission
Standard
Type:
4-speed Automatic Transmission (4G-Tronic)
Optional
Type:
5-speed Manual Transmission
Features
Automatic Modes:
Standard (S) and Economy (E) modes
Fluid Specifications
Automatic Transmission Fluid Type:
Mercedes-Benz 236.1 specification (e.g., ATF Dexron III equivalent)
Fluid Capacity
Automatic Transmission Fluid Capacity:
Approx. 6-7 Liters (for full service)
📐 Dimensions
Exterior
Length:
4420 mm (174 in)
Width:
1710 mm (67.3 in)
Height:
1390 mm (54.7 in)
Wheelbase
Wheelbase:
2665 mm (104.9 in)
Weights
Curb Weight:
Approx. 1300-1400 kg (2866-3086 lbs)
Gross Vehicle Weight Rating:
Approx. 1850 kg (4078 lbs)
Cargo
Trunk Capacity:
Approx. 400 Liters (14.1 cu ft)
🛡️ Safety Features
Ratings
Crash Test History:
While official specific ratings for this era are less standardized than today, the W201 chassis was recognized for its robust safety cell and designed to meet stringent safety standards of its time.
Active Features
Brakes:
Front: Ventilated Disc, Rear: Solid Disc
ABS:
Anti-lock Braking System (ABS) often standard or optional on higher trims
Passive Features
Airbags:
Driver's airbag typically standard from mid-production onwards, passenger airbag optional/later addition.
Seatbelts:
3-point inertia-reel seatbelts front and rear
Body Structure:
Reinforced safety cell, crumple zones
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM cassette stereo system, often with amplifier. Manual covers basic troubleshooting and component identification.
Driver Assistance
Cruise Control:
Optional cruise control system available, covered in the manual.
Climate Control
HVAC System:
Manual or automatic climate control systems. Manual details component operation, refrigerant, and basic diagnostics.
Connectivity
Wiring Diagrams:
Detailed electrical wiring diagrams are a key feature of this manual, crucial for diagnosing electronic issues.
🔧 Maintenance
Service Intervals
Oil And Filter Change:
Every 10,000 km (6,000 miles) or 12 months, whichever comes first.
Air Filter Replacement:
Every 30,000 km (18,000 miles) or 24 months.
Fuel Filter Replacement:
Every 30,000 km (18,000 miles) or 24 months.
Spark Plug Replacement:
Every 50,000 km (30,000 miles) or 48 months (for standard plugs).
Fluid Specifications
Brake Fluid Type:
DOT 3 or DOT 4
Power Steering Fluid Type:
Mercedes-Benz specification (e.g., CHF 11S or equivalent, consult manual)
Known Issues
Common Problems 1:
Head gasket leaks (especially at the rear of the engine), oil leaks from valve cover and oil pan gaskets, front suspension ball joint wear, vacuum hose degradation, MAF sensor issues (if applicable to later models in the range), fuel distributor/accumulator issues on older KE-Jetronic systems.
Common Problems 2:
Wiring harness degradation (especially insulation), window regulator failures, evaporator core leaks (causing AC issues), dashboard instrument cluster failures.
Repair Considerations
Complexity:
Designed with Mercedes-Benz engineering, requiring specific tools and knowledge for optimal repair. The manual addresses this complexity.
📚 Vehicle History
Brand Heritage
Mercedes Benz Legacy:
Pioneering safety, engineering, and quality since the early 20th century.
Model Evolution
W201 Introduction:
Introduced in 1982 as the 'Baby Benz', aiming to offer Mercedes-Benz quality and engineering in a more compact and affordable package.
190E 2.6 Introduction:
The 2.6-liter engine (M103) was introduced in 1986, offering a significant upgrade in performance and smoothness over the earlier 2.3 and 2.3-16 models.
Production
Production Period:
1982-1993
Manufacturing Plant:
Bremen, Germany
🏆 Awards & Recognition
Recognitions
Historical Reputation:
The W201 series, including the 190E 2.6, is highly regarded for its build quality, longevity, and driving dynamics, often considered a benchmark in its class during its production run.
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