Mercedes 190 W201 Workshop Repair and Service Manual PDF 1985-1993

Mercedes 190 W201 Workshop Repair and Service Manual PDF: Engines, Gearboxes, Chassis & Body

This Mercedes 190 W201 workshop repair manual PDF runs to 4,751 pages for the 190 sedan from 1985 to 1993, in two parts. The first is 1,338 Mercedes-Benz dealer documents on the chassis, steering, brakes, climate control, body and electrics. The second covers the North American 190E and 190D engines, fuel injection, gearboxes, wiring and service bulletins. The coverage list below shows what each part holds.

Model:
Mercedes-Benz 190, series W201 sedan: 190, 190 E, 190 E 1.8, 190 E 2.3, 190 E 2.6, 190 E 2.3-16, 190 E 2.5-16 and Evolution, plus the OM601 and OM602 diesel models

Engines:
Petrol, Gasoline
M102 2.3 (102.985): full engine repair and overhaul, CIS-E fuel injection
M103 2.6 (103.942): full engine repair and overhaul, CIS-E fuel injection
M102 1.8, 2.0, 2.3-16 and 2.5-16: specifications and service items only

Diesel:
OM601 2.2 (601.921), OM602 2.5 (602.911) and 2.5 Turbo (602.961): removal, cylinder head, timing, pistons and crankshaft, injection pump timing
Other OM601 and OM602 models: dealer removal and cylinder head procedures

Transmissions:
Automatic W4A020 and W4A040: removal, servicing and overhaul
Five speed manual GL 68/20: removal and overhaul
Clutch repair, master and slave cylinder

Years: 1993, 1992, 1991, 1990, 1989, 1988, 1987, 1986, 1985

Format: PDF

Languages: English

Left and right hand drive covered.

Compatibility:
Windows 11, 10, 8, 7, Vista, XP, Mac, Linux, Android, iOS + All Tablets & Phones. A 73 MB file that downloads quickly and keeps easily on a phone or tablet.

CONTENTS:
Service: maintenance service sheets, technical data, jacking up and towing.- Engine: removal, cylinder head, timing chain, pistons and crankshaft for the 2.3, 2.6 and diesel engines.- Fuel and emissions: Bosch CIS-E injection, diesel injection pump timing, turbocharger, ignition and EGR.- Cooling: coolant pump, radiator, fans and drive belts.- Drivetrain: clutch, automatic and manual gearbox overhaul and propeller shaft.- Suspension: springs, shock absorbers and level control.- Axles and wheels: front axle, rear axle, final drive, automatic locking differential and alignment.- Brakes: service and parking brake, ABS and ASR.- Steering: steering gear, power steering pump and steering lock.- Electrics: alternator, starter, fuses, instruments, lights, wipers and cruise control.- Wiring: engine management and full system wiring diagrams.- Comfort: central locking, anti-theft alarm, radio and telephone.- Climate: heating, air conditioning and auxiliary heater.- Body: panels, doors, windows, sliding roof, seats, belts, airbag and paintwork.- Bulletins: technical service bulletins, campaigns and safety recalls.

Special Features:
4,751 pages for the 190 W201 in two parts
1,338 Mercedes-Benz dealer documents in 47 system groups
2,316 pages of North American 190E and 190D repair data
4,379 bookmarks and a clickable contents page covering both parts
Engine and automatic gearbox overhaul procedures
195 pages of wiring diagrams
240 special tool sheets

Coverage, page by page:
Part 1, 2,434 pages of Mercedes-Benz dealer documents, handles the chassis, body and electrics in depth. The rear axle and final drive alone take 385 pages, steering 264, climate control 213, seats and restraint systems 164, brakes with ABS and ASR 127, suspension and level control 122 and wheels and alignment 115. It also has full clutch repair and the OM601 and OM602 diesel removal and cylinder head work.
Part 2, 2,316 pages for the North American 190E and 190D, brings the engine side: engine mechanical and overhaul (288 pages), fuel injection, ignition and engine controls (288), starting, charging and instruments (80), automatic and manual gearbox overhaul with clutch (136), wiring diagrams (195) and technical service bulletins, campaigns and recalls (1,275).
Still missing: engine repair for the 16 valve engines, overhaul procedures for the European-only 1.8 and 2.0 petrol engines, and internal diesel injection pump repair. Around 314 scanned pages in Part 1 carry no searchable text, while every page of Part 2 does.

Mercedes 190 W201 PDF Cover Image with Table of Contents

Mercedes 190 W201 Steering Knuckle and Front Axle PDF Download

Mercedes 190 W201 Clutch Master Cylinder PDF Download

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Frequently Asked Questions

What engine work does the 190 W201 PDF cover?
Full mechanical repair for the North American engines: the 2.3 four cylinder and 2.6 six cylinder petrol engines and the 2.2, 2.5 and 2.5 Turbo diesels, from removal and cylinder head work down to pistons and crankshaft. The OM601 and OM602 diesels also get the dealer procedures in Part 1.

Can the 190 W201 automatic gearbox be rebuilt with this manual?
Yes. The W4A020 and W4A040 automatics have a full overhaul section along with removal, servicing and shift linkage adjustment, and the GL 68/20 five speed manual has its own overhaul and removal procedures.

What is still missing from the 190 W201 manual?
Engine repair for the 16 valve 2.3-16 and 2.5-16, overhaul procedures for the European-only 1.8 and 2.0 petrol engines, and internal repair of the diesel injection pump. Part 2 follows the North American cars, so its emission equipment matches the US versions.

Does the 190 W201 PDF include engine management wiring diagrams?
Yes. The North American section has engine performance wiring diagrams and component locations for the 190E, plus starting and charging, air conditioning, lighting and power accessory circuits, 195 pages in all.

Is the 190 W201 steering box covered?
Yes. Steering takes 264 pages: steering gear design and function, the power steering pump, steering lock, contact spiral and speed-sensitive power steering.

Can I work on the W201 heating and air conditioning with it?
Yes. Climate control is one of the largest groups at 213 pages, covering the heater box, heater valve, blower, air flaps, air conditioning and the auxiliary heater.

Is there a W201 workshop software version as well?
Yes. If you are looking for the Professional Workshop Manual Software for this manual, see the Mercedes W201 professional workshop manual software. The rest of our older Mercedes manuals are listed in the Mercedes classic cars workshop manual range.