Mercedes-benz 190D 190Db 190SL Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Mercedes-Benz Model: 190D / 190Db / 190SL Codes Chassis Codes: W201 (190D, 190Db), W121 (190SL) 👋 Introduction Market Position Market Position W201: The W201 (190D/190Db)...

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标签: 190D 190Db 190SL Car Cars Mercedes Mercedes-benz Misc

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Description

🏷️ Basic Information

Identification

Make:

Mercedes-Benz

Model:

190D / 190Db / 190SL

Codes

Chassis Codes:

W201 (190D, 190Db), W121 (190SL)

👋 Introduction

Market Position

Market Position W201:

The W201 (190D/190Db) was Mercedes-Benz's entry into the compact executive sedan segment, aiming for broader market appeal with robust engineering and Mercedes-Benz quality.

Market Position W121:

The W121 (190SL) was a stylish and relatively affordable sports car, positioned below the iconic 300SL, offering a blend of performance and open-top motoring.

Competitive Analysis

W201 Competitors:

BMW 3 Series (E30), Audi 80/90, Saab 900, Volvo 240.

W121 Competitors:

Alfa Romeo Spider, Triumph TR3/TR4, Austin-Healey 100/3000, MG A.

Key Features

W201 Engineering:

Known for its solid build quality, advanced multilink rear suspension (unique for its class), and durable diesel engines.

W121 Design:

Classic European styling, a charming convertible experience, and a reliable platform for spirited driving.

📋 Manual Details

Coverage Areas

Coverage Summary:

Comprehensive workshop service and repair for Mercedes-Benz 190D (W201), 190Db (W201), and 190SL (W121) models.

Page Count

Page Count:

Manual Type

Manual Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete engine disassembly, assembly, inspection, and repair for diesel and gasoline variants, including cylinder head, block, crankshaft, pistons, connecting rods, camshafts, timing systems.

Fuel System:

Diesel injection systems (e.g., Bosch inline injection pumps), fuel tanks, lines, filters, glow plug systems, gasoline fuel delivery and injection (if applicable to specific variants covered).

Cooling System:

Radiator, fan, water pump, thermostat, coolant passages, hoses, and troubleshooting.

Exhaust System:

Exhaust manifolds, pipes, mufflers, catalytic converters (if applicable), and hangers.

Transmission Manual:

Manual transmission disassembly, assembly, inspection, clutch operation, and related components.

Transmission Automatic:

Automatic transmission (e.g., 4-speed or 5-speed) overhaul, adjustments, troubleshooting, and hydraulic systems (if applicable to covered models).

Drivetrain Rear Axle:

Differential, drive shafts, CV joints, axle shafts, and wheel bearings.

Suspension Front:

MacPherson struts, control arms, ball joints, tie rod ends, steering knuckles, springs, and shock absorbers.

Suspension Rear:

Multi-link independent rear suspension (IRS) for W201, trailing arms, shock absorbers, springs, and alignment specifications.

Steering System:

Power steering pump, steering gear/rack, steering column, linkages, and troubleshooting.

Brakes Front:

Disc brake calipers, rotors, pads, hoses, and hydraulic lines.

Brakes Rear:

Disc or drum brake systems, calipers/wheel cylinders, rotors/drums, pads/shoes, parking brake mechanism.

Electrical System Charging:

Alternator, voltage regulator, battery, wiring harnesses, and troubleshooting.

Electrical System Ignition:

Distributor, ignition coil, spark plugs, ignition wires, electronic ignition control (if applicable).

Electrical System Lighting:

Headlights, taillights, interior lights, wiring diagrams, and bulb replacement.

Electrical System Accessories:

Wipers, washers, horn, power windows, central locking, power mirrors, heating, ventilation, and air conditioning (HVAC) controls.

Body Exterior:

Body panel removal/installation, doors, hood, trunk lid, bumpers, glass replacement, weatherstripping.

Body Interior:

Dashboard, seats, door panels, headliner, carpet, trim components.

Procedures Included

Maintenance Scheduled:

Detailed intervals for oil changes, filter replacements, fluid checks, belt inspections, spark plug/glow plug replacement, brake inspections, and more.

Troubleshooting Diagnostics:

Systematic diagnostic procedures for common and uncommon faults, including symptom-based troubleshooting trees.

Repair Engine:

Step-by-step instructions for engine rebuilding, head gasket replacement, timing chain/belt replacement, component repair.

Repair Transmission:

Complete procedures for manual and automatic transmission rebuilds, clutch replacement, torque converter service.

Repair Brakes:

Brake caliper rebuilding, rotor replacement, hydraulic system bleeding, parking brake adjustment.

Repair Electrical:

Wiring diagram interpretation, component testing, starter motor and alternator replacement, fuse and relay troubleshooting.

Body Repair:

Dent repair, panel replacement, welding procedures (if specified), glass installation.

Specifications Torque:

Comprehensive torque specifications for all critical fasteners (engine, chassis, suspension, brakes).

Specifications Alignment:

Front and rear wheel alignment angles (camber, caster, toe), steering wheel centering.

Technical Depth

Depth:

Extremely high. Covers routine maintenance, minor repairs, major overhauls, and complete system diagnostics and rebuilding.

📊 Manual Specifications

File Format

File Format:

Searchable PDF

Print Quality

Print Quality:

High-resolution scans suitable for printing.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine W201

Engine Codes Diesel:

OM601 (2.0L Diesel), OM602 (2.5L Diesel), OM602.911 (2.5L Turbo Diesel, later models).

Primary Engine W121

Engine Codes Gasoline:

M121 (1.9L Inline-4 Gasoline), M121 (2.3L Inline-4 Gasoline for 190SL).

Performance W201 Diesel

Horsepower Range Diesel:

Approximately 72 hp (190D) to 94 hp (190Db) and 125 hp (190D 2.5 Turbo).

Torque Range Diesel:

Approximately 130 Nm (190D) to 160 Nm (190Db) and 225 Nm (190D 2.5 Turbo).

Performance W121

Horsepower W121:

Approximately 104 hp (1.9L), 120 hp (2.3L).

Torque W121:

Approximately 149 Nm (1.9L), 173 Nm (2.3L).

Fuel System W201 Diesel

Fuel Injection Type:

Mechanical Direct Injection (Bosch)

Fuel System W121

Fuel System Type:

Carbureted (e.g., Solex Zenith twin-choke) or Bosch mechanical fuel injection depending on specific variant.

🔧 Transmission

Standard W201

Standard Transmission W201:

4-speed manual

Optional W201

Optional Transmission W201:

4-speed automatic (722.4) or 5-speed automatic (722.5) on later models.

Standard W121

Standard Transmission W121:

4-speed manual

Optional W121

Optional Transmission W121:

None (manual was standard and only option).

Features Automatic

Automatic Features:

Hydraulic torque converter, planetary gear sets, hydraulic valve body control.

📐 Dimensions

Exterior W201

Length W201:

Approx. 4420 mm (174 in)

Width W201:

Approx. 1710 mm (67.3 in)

Height W201:

Approx. 1390 mm (54.7 in)

Exterior W121

Length W121:

Approx. 4010 mm (157.9 in)

Width W121:

Approx. 1710 mm (67.3 in)

Height W121:

Approx. 1320 mm (52 in)

Weights W201

Curb Weight W201:

Approx. 1300-1450 kg (2866-3200 lbs) depending on engine and options.

Weights W121

Curb Weight W121:

Approx. 1150 kg (2535 lbs)

Wheelbase W201

Wheelbase W201:

Approx. 2665 mm (104.9 in)

Wheelbase W121

Wheelbase W121:

Approx. 2270 mm (89.4 in)

🛡️ Safety Features

Ratings W201

Safety Philosophy W201:

Designed with advanced safety features for its era, including a rigid passenger cell and safety-conscious interior design.

Active Features W201

Active Safety W201:

Four-wheel disc brakes (standard on most models), power-assisted steering, advanced suspension geometry for stability.

Passive Features W201

Passive Safety W201:

Crumple zones, reinforced A, B, and C pillars, padded dashboard, optional driver's airbag (later models).

Ratings W121

Safety Features W121:

While not subject to modern crash testing standards, it featured a sturdy chassis and a well-engineered body structure for its time.

💡 Technology Features

Infotainment W201

Infotainment Features W201:

Basic analog radio systems (AM/FM, often with cassette player), manual climate control, analog gauges.

Driver Assistance W201

Driver Assistance W201:

Anti-lock Braking System (ABS) available on some later models.

Connectivity W201

Connectivity W201:

N/A (No factory integrated connectivity features like Bluetooth or USB).

Infotainment W121

Infotainment Features W121:

Basic analog radio, manual convertible top operation, simple dashboard layout.

🔧 Maintenance

Service Intervals W201 Diesel

Oil Change Interval Diesel:

Every 7,500-10,000 miles (12,000-15,000 km) or 1 year, whichever comes first, depending on driving conditions.

Air Filter Interval Diesel:

Inspect every 15,000 miles (24,000 km), replace as needed or every 30,000 miles (48,000 km).

Fuel Filter Interval Diesel:

Replace every 15,000-30,000 miles (24,000-48,000 km), depending on fuel quality and driving.

Fluid Specifications W201

Engine Oil Spec Diesel:

API CD or CE specification, SAE 10W-40 or 15W-40 depending on climate.

Coolant Spec W201:

MB Approved Antifreeze/Coolant (e.g., G05 or similar based on glycol type and corrosion inhibitors).

Transmission Fluid Auto Spec:

MB 236.1 or MB 236.2 (ATF Dexron II or Mercon compatible).

Fluid Specifications W121

Engine Oil Spec Gasoline:

API SF or SG, SAE 20W-50 or 10W-30 depending on climate.

Known Issues W201

Common W201 Issues:

Biodegradable wiring insulation (may require replacement), vacuum line degradation, early model overheating (due to design), rust in common areas (wheel arches, sills), suspension bushing wear.

Known Issues W121

Common W121 Issues:

Carburetor tuning and leaks, ignition system reliability, oil leaks from engine seals, chrome trim corrosion, soft top wear.

📚 Vehicle History

Brand Heritage

Mercedes Benz Heritage:

Founded on innovation and engineering excellence, Mercedes-Benz has a long history of producing robust and technologically advanced vehicles.

Model Evolution W201

W201 Development Codeword:

'Baby Benz', designed by Bruno Sacco.

W201 Introduction Year:

Model Evolution W121

W121 Introduction Year:

W121 Legacy:

Succeeded by the W113 'Pagoda' SL.

Production

W201 Production Years:

1982-1993

W121 Production Years:

1955-1963

W201 Production Locations:

Mainly Sindelfingen, West Germany.

W121 Production Locations:

Mainly Stuttgart, West Germany.

🏆 Awards & Recognition

Recognitions W201

Design Award W201:

The W201's design by Bruno Sacco won the prestigious Italian Car Design Award.

Reliability Reputation W201:

Often cited for its robust construction and longevity, particularly the diesel variants.

Recognitions W121

Classic Status W121:

Highly regarded as a classic sports car, appreciated for its style, driving experience, and historical significance.