Mercedes-Benz Service Manual Chassis & Body Model 201

$20.00

Mercedes-Benz W201 workshop manual with chassis and body technical information

Includes factory documentation for vehicle identification, technical data, suspension, axles, steering, brakes, bodywork, interior, electrical equipment and inspection, adjustment, repair and installation procedures, with direct application to 190 E, 190 E 2.3, 190 E 2.3-16, 190 E 2.6, 190 D 2.2, 190 D 2.5 and 190 D 2.5 Turbo versions of the Series 201.

English PDF | 966 pages | Instant digital delivery.

Applicable to 190 E and 190 D versions of the Series 201
Includes suspension, axles, steering, brakes, bodywork, interior and electrical system
Technical procedures for maintenance, repair and restoration
Useful reference for workshops and Mercedes-Benz W201 owners

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Description
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Mercedes-Benz Service Manual Chassis & Body Model 201 | PDF

Mercedes-Benz W201 workshop manual with factory technical information covering chassis, bodywork, suspension, brakes, steering, interior and electrical equipment for Series 201 models.

This manual corresponds to the official Mercedes-Benz documentation for W201 models, commercially known as the Mercedes-Benz 190. It is a complete technical reference for maintenance, repair and restoration work related to the vehicle chassis and body.

It includes inspection, removal, adjustment, repair and installation procedures for the main structural and mechanical systems of the Mercedes-Benz W201, with useful information for specialist workshops, owners, restorers and collectors.

Main topics covered in this Mercedes-Benz Series W201 manual

Vehicle identification, chassis number locations and general technical data.
Engine electrical system, alternator, regulator and starter motor.
Chassis suspension, shock absorbers, springs and stabilizer bars.
Front axle, rear axle, wheels and propeller shaft.
Hydraulic brakes, mechanical brakes and brake vacuum system.
Steering, control components, adjustments and repair procedures.
Body electrical system and vehicle electrical equipment.
Glass, windows, interior, doors, sliding roof and central locking system.
Detachable body components, seats and restraint system.
Technical supplements corresponding to Series 201 updates.

Mercedes-Benz models included in this manual

The manual indicates direct application for the following Mercedes-Benz Series 201 models:

190 E 2.3, 190 E 2.3-16 and 190 E 2.6
190 D 2.2, 190 D 2.5 and 190 D 2.5 Turbo

It may also be useful for other Mercedes-Benz W201 versions

Although direct application corresponds to the models listed above, the chassis, bodywork, suspension, steering, brakes, interior, doors, glass and electrical equipment sections may serve as a reference for other Series 201 versions, always checking year, market, chassis number, engine and specific equipment.

Mercedes-Benz 190
Mercedes-Benz 190 E 1.8 and 190 E 2.0
Mercedes-Benz 190 E 2.5-16, 190 E 2.5-16 Evolution and Evolution II
Mercedes-Benz 190 D and 190 D 2.0

Important: This product corresponds to the chassis and body manual for the Series 201. For complete vehicle coverage, Mercedes-Benz organized technical information into separate manuals for engine, transmission, chassis and body, and heating / air conditioning. For specific engine, gearbox or climate control work, the corresponding system manual may be required.

Item details

Format: PDF
Language: English
Pages: 966
File size: 43.1 MB
Delivery method: download link

Frequently asked questions

Can it be used as a reference for other Mercedes-Benz W201 versions?

Yes. Although direct application corresponds to the models listed above, it may be useful as a reference for other W201 versions, especially in chassis, bodywork, suspension, brakes, steering, interior and electrical equipment sections. Before applying any procedure, year, market, chassis number, engine and specific equipment should be checked.

What type of information does it include?

It includes chassis and body technical information: suspension, axles, brakes, steering, interior, glass, doors, sliding roof, central locking system, seats, restraint system and electrical equipment.

Is it useful for restoration work?

Yes. It is a very useful reference for restoration, maintenance and repair, especially when original removal, inspection, adjustment and installation procedures are needed.

Is the file delivered printed or digitally?

It is delivered as a digital PDF file, available for immediate download after purchase.

Mercedes-Benz W201 Chassis and Body Manual | Index

This index lists the main sections and job numbers included in the Mercedes-Benz Service Manual Chassis & Body Series 201.

Each entry is listed in accordance with the manual’s original technical layout and numbering.

00 General, technical data

00-005 Instructions for use of service manual
00-010 Engine and vehicle identification
00-015 Vehicle identification number locations
00-020 Technical data

15 Electrical system of engine

15-600 Testing alternator with regulator in vehicle
15-642 Renewing fan assembly
15-700 Removal and installation of starter

32 Chassis suspension system

32-100 Removal and installation of damper strut
32-110 Removal and installation of rear shock absorber
32-120 Checking damper strut (front axle)
32-121 Checking shock absorber (rear axle)
32-200 Removal and installation of front spring
32-300 Removal and installation of torsion bar on front axle
32-310 Removal and installation of torsion bar on rear axle

33 Front axle

33-200 Removal and installation of front axle half
33-300 Adjusting end play of wheel bearings
33-310 Removal and installation of front wheel hub
33-320 Disassembling, checking, reconditioning and assembling front wheel hub
33-400 Removal and installation of steering knuckle
33-410 Checking steering knuckle
33-420 Removal and installation of steering knuckle arm
33-425 Checking supporting joint of the steering knuckle bearing
33-430 Renewing the sleeve for the supporting joint of the steering knuckle bearing mount
33-440 Renewing supporting joint of steering knuckle bearing
33-510 Removal and installation of wishbone
33-525 Checking bearing of wishbone
33-526 Renewing rubber mounts of wishbone
33-530 Checking wishbone (for vehicles following accident)

35 Rear axle

35-010 Removal and installation of complete rear axle
35-040 Removal and installation of front and rear rubber mounts of rear axle suspension
35-110 Removal and installation of camber strut
35-111 Removal and installation of pulling strut
35-112 Removal and installation of track rod, renewing rubber mounts
35-113 Removal and installation of pushing strut
35-114 Removal and installation of spring link, renewing rubber mount and supporting joint
35-115 Removal and installation of wheel carrier
35-130 Removal and installation of rear axle shaft flange with angular ball bearing
35-520 Removal and installation of rear axle center piece
35-530 Renewing radial sealing ring on drive pinion
35-540 Renewing radial sealing ring on connecting flange of rear axle shaft
35-550 Disassembly and assembly of rear axle center piece, adjustment of wheel set
35-560 Reconditioning of differential
35-620 Removal and installation of rear axle shaft
35-660 Renewing rubber sleeves on rear axle shaft
35-670 Removal and installation of connecting flange of rear axle shaft

40 Wheels

40-010 Lifting vehicle with vehicle jack
40-013 Positioning of jacking-up shoes and jacks
40-100 Survey rims and tires
40-102 Rims
40-104 Tires
40-106 Tire inflation pressure
40-108 Snow chains
40-110 Removing and mounting of wheels
40-113 Removing and mounting hub cap for forged light alloy rims

41 Propeller shaft

41-050 Removal and installation of propeller shaft
41-100 Removal and installation of propeller shaft intermediate bearing, replacement of radial ball bearing
41-200 Replacement of centering sleeve

42 Brakes, hydraulic and mechanical

42-005 General information
42-010 Bleeding the brake system or renewing the brake fluid
42-012 Checking brake lines and brake hoses
42-015 Checking the brake system for leaks
42-035 Checking warning device in expansion tank
42-040 Checking and adjusting or removal and installation of mechanical stop lamp switch
42-110 Removal and installation of floating caliper on front axle
42-120 Removal and installation of fixed caliper on rear axle
42-160 Replacing brake pads
42-220 Removal and installation of brake disk on front axle
42-228 Removal and installation of brake disk on rear axle
42-260 Cleaning brake disks
42-310 Removal and installation of stepped tandem main cylinder
42-315 Disassembly, checkup and assembly of stepped tandem main cylinder
42-510 Removal and installation of parking brake lever
42-520 Removal and installation of front brake cable control
42-525 Removal and installation of rear brake cable control
42-530 Removal and installation of brake shoes of parking brake
42-540 Readjusting or adjusting brake shoes of parking brake

43 Brakes, vacuum system

43-023 Testing check valve
43-325 Checking brake unit
43-350 Removal and installation of brake unit
43-618 Removal and installation of piston vacuum pump
43-660 Testing piston vacuum pump

46 Steering

46-110 Checking play of steering components
46-120 Checking start of manual restriction
46-130 Checking oil pressure of power steering pump
46-412 Steering gear - removal and installation of power steering
46-510 Removal and installation of pitman arm
46-520 Removal and installation of intermediate steering arm
46-540 Removal and installation of track rod
46-550 Removal and installation of drag link
46-560 Replacement of sleeves for ball joints of track rod and drag link
46-610 Removal and installation of steering wheel
46-640 Removal and installation of steering lock
46-710 Removal and installation of power steering pump
46-010 Differentiating characteristics of steering gears
46-220 Reconditioning of steering gear
46-720 Disassembly, checkup and reconditioning of power steering pump
46-740 Assembly of power steering pump

54 Electrical system

54-005 Battery test, service and maintenance
54-100 Designation and layout of ground connecting points
54-140 Central electrics
54-150 Central electrics, remove and install
54-152 Electric connections of special equipment
54-250 Removal and installation of instrument cluster
54-251 Removal and installation of indicating instruments
54-253 Removal and installation of speedometer
54-255 Checking indicator for economic driving (ECONOMY)
54-256 Operation of transmitter for fuel gauge
54-257 Testing fuel gauge
54-258 Removal and installation of time clock/revolution counter
54-261 Testing electric outside temperature indicator
54-262 Renewing lamp carrier with acoustic turn signal checkup
54-264 Checking washer water level indicator
54-266 Operation of auxiliary instruments model 201.034
54-267 Removal and installation of auxiliary instruments
54-395 Sun visor with illuminated mirror
54-410 Warning device for safety belt, ignition key, light USA
54-500 Operation
54-504 Testing with adapter
54-506 Testing coding plug
54-541 Removal and installation of actuator
54-545 Removal and installation of switch, cruise control/Tempomat
54-550 Removal and installation of transmitter
54-561 Adjusting connecting rod
54-566 Removal and installation of coding plug
54-575 Removal and installation of switch on clutch pedal
54-579 Layout of plug connections

67 Glass and windows

67-100 Removal and installation of windshield glass
67-120 Removal and installation of ornamental frame on windshield
67-200 Removal and installation of rear window
67-220 Removal and installation of ornamental frame on rear window

68 Interior equipment

68-100 Removal and installation of instrument panel
68-105 Removal and installation of cover for speaker
68-120 Removal and installation of glove box cover
68-130 Removal and installation of lock on glove box cover
68-140 Removal and installation of glove box
68-150 Removal and installation of cover under instrument panel
68-200 Removal and installation of center console
68-230 Removal and installation of cover on shift lever
68-231 Removal and installation of cover on shift lever (automatic transmission)
68-400 Removal and installation of reveal molding on windshield top
68-405 Removal and installation of reveal molding laterally on windshield
68-430 Removal and installation of headlining
68-442 Removal and installation of edge protection under driver’s and rear door
68-449 Removal and installation of paneling (trim) on rear pillar
68-458 Removal and installation of hat rack
68-470 Removal and installation of panelling (trim) on center pillar
68-485 Removal and installation of panelling (trim) on rear center piece
68-492 Removal and installation of damping elements on transmission tunnel, outside
68-495 Removal and installation of cover on rear pillar, outside

72 Doors

72-050 Removal and installation of driver’s door
72-051 Renewing driver’s door
72-060 Removal and installation of rear compartment door
72-061 Renewing rear compartment door
72-100 Removal and installation of door lining on driver’s door
72-101 Removal and installation of door lining on rear door
72-140 Removal and installation of hand grip on door lining
72-160 Removal and installation of sealing rail inside
72-170 Removal and installation of sealing rail outside
72-185 Removal and installation of electric window opener on driver’s door
72-187 Removal and installation of electric window opener on rear door
72-197 Removal and installation of stationary window on rear door
72-198 Removal and installation of flexible window run channel
72-210 Removal and installation of door holder
72-220 Removal and installation of sealing frame on driver’s or rear door
72-230 Removal and installation of inside door actuation on driver’s door
72-231 Removal and installation of inside door actuation on rear door
72-240 Removal and installation of outside door handle on driver’s door
72-241 Removal and installation of outside door handle on rear door
72-250 Removal and installation of door lock on driver’s door
72-251 Removal and installation of door lock on rear door

77 Sliding roof

77-050 Removal and installation of headlining on sliding-lifting roof
77-100 Removal and installation of sliding roof cover
77-110 Adjustment of sliding roof cover
77-130 Removal and installation of sealing and holding rails on sliding-lifting roof cutout
77-140 Removal, installation and adjustment of teleflex control
77-150 Removal and installation of teleflex tube (sliding roof electrical, sliding-lifting roof)
77-170 Removal and installation of lifting angle on sliding-lifting roof
77-180 Removal and installation of motor and gearbox (sliding roof electrical, sliding-lifting roof)
77-195 Testing and adjusting slip clutch of sliding roof motor (sliding roof electrical, sliding-lifting roof)
77-250 Removal and installation of wind deflector on sliding roof (sliding roof mechanical, electrical, sliding-lifting roof)
77-300 Removal and installation of sliding roof frame (sliding roof electrical, sliding-lifting roof)

80 Central locking system

80-010 Functional description
80-090 Checking function of central locking system
80-104 Checking electrical function of the central locking system
80-108 Checking pneumatic function of the supply pump
80-110 Checking electrical function of the switch in the driver’s door
80-116 Checking pneumatic function of the element
80-120 Checking central locking system for leaks
80-205 Removal and installation of electric switch in the driver’s door
80-210 Removal and installation of element in front passenger door
80-220 Removal and installation of rear door element
80-230 Removal and installation of tank flap element
80-240 Removal and installation of trunk lid element
80-270 Removal and installation of supply pump
80-800 Electrical wiring diagram
80-900 Function diagram
80-010 Functional description
80-090 Checking function of central locking system
80-104 Checking electrical function of the central locking system
80-108 Checking pneumatic function of the supply pump
80-112 Checking electrical function of the control and working element
80-116 Checking pneumatic function of the element
80-120 Checking central locking system for leaks
80-215 Removal and installation of control and working element (S47, S48, S49)
80-220 Removal and installation of rear door element
80-230 Removal and installation of tank flap element
80-270 Removal and installation of supply pump (M14/1)
80-800 Electrical wiring diagrams
80-900 Function diagrams

82 Electrical system of body

82-010 Removal and installation of dome lamps front and rear
82-040 Adjusting lamps, front
82-052 Removal and installation of lamp unit
82-062 Removal and installation of lamp unit bulbs
82-067 Removal and installation of lamp unit glass
82-252 Removal and installation of tail lamp unit
82-348 Removal and installation of licence plate lamp
82-395 Electric wiring diagram, heatable rear window
82-505 Removal and installation of radio
82-512 Removal and installation of speaker, front and rear
82-530 Operation of automatic antenna USA
82-535 Removal and installation of antenna
82-610 Removal and installation of profilated rubber of wiper blade
82-680 Removal and installation of wiper motor
82-760 Removal and installation of wiper linkage
82-765 Removal and installation of rubber seal under wiper gears
82-785 Electric wiring diagram of wiping-washing system
82-795 Windshield washer
82-800 Operation of seat heater
82-833 Electrically adjustable outside rear view mirror
82-834 Outside rear view mirror with electrically heated plate glass
82-860 Electrical seat adjustment, front
82-865 Removal and installation of switch for electrical seat adjustment
82-980 Operation of anti-theft warning system (EBW)

88 Detachable body components

88-100 Removal and installation of front fender
88-200 Removal and installation of front bumper
88-210 Disassembly and reassembly of bumper front and rear
88-220 Removal and installation of rear bumper
88-300 Removal and installation of engine hood
88-302 Adjustment of engine hood
88-306 Removal and installation of engine hood hinge
88-310 Removal and installation of cable control for engine hood
88-320 Removal and installation of engine hood lock
88-400 Removal and installation of radiator shell
88-401 Removal and installation of radiator grille
88-402 Removal and installation of trim strips on radiator grille
88-405 Removal and installation of Mercedes star
88-500 Removal and installation of trunk lid
88-502 Removal and installation of trunk lid lock
88-505 Mounting the model identification on trunk lid
88-512 Removal and installation of hinge lever for trunk lid
88-800 Removal and installation of paneling on side wall
88-802 Removal and installation of protective strip on side wall
88-810 Removal and installation of panelling on doors and fenders, outside (model 201.034)
88-820 Removal and installation of rear spoiler
88-825 Marking and drilling holes for rear spoiler on trunk lid
88-830 Removal and installation of panelling on side member (model 201.034)
88-855 Removal and installation of rain strip on front wall pillar and roof
88-900 Removal and installation of outside rear view mirror
88-905 Removal and installation of electrically adjustable outside rear view mirror
88-910 Removal and installation of motor for electrically adjustable outside rear view mirror

91 Seats, restraint systems

91-100 Removal and installation of driver’s seat
91-110 Removal and installation of front passenger’s seat
91-170 Removal and installation of rear seat and rear seat backrest
91-180 Removal and installation of cover on driver’s seat cushion
91-182 Removal and installation of cover on driver’s seat backrest
91-500 Removal and installation of front safety belt
91-510 Removal and installation of rear safety belt
91-550 Exchange instructions for safety belts

A Supplement 201.034

32 Suspension
33 Front axle
35 Rear axle
40 Chassis measurements, Wheels and tires
42 Brakes
46,47 Steering
49 Exhaust system
54 Electrical system
68 Interior
82 Electrical system, radio, dome lamp
83 Tempmatic climate control
88 Detachable body components, external paneling
91 Seats, restraint systems

B Supplement 1986

32 Suspension
35 Rear axle
54 Cruise control
80 Wiring diagram

C Supplement 1987

29, 32 Pedals, Suspension
33 Front axle
35 Rear axle
40 Wheels, chassis measurements
41,42 Propeller shaft, Brakes
46,49 Steering, Exhaust system

D Supplement 1988

54 Cruise control system
77 Sliding roof
82 Anti-theft alarm system