Haynes Mercedes-Benz 190 (Petrol) Owners Workshop Manual 0856969281, 9780856969287

Citation preview

r

L

L Y

r

L

o

L

©) ©

Ae

1983 to 1987 0 1997 cc

Owners Workshop Manual

Digitized by the Internet Archive in 2022 with funding from Kahle/Austin Foundation

https://archive.org/details/mercedesbenz19000000mead

Mlercedes-Benz 190 Owners

Workshop Manual John S Mead Models covered Mercedes-Benz 190 & 190 E 1997 cc petrol engine Does not cover Diesel engine, 190 E 2.3-16 or 190 E 2.6 models

ABCDE FGHIJ KLMNO

PORST

Haynes Publishing Sparkford Nr Yeovil Somerset BA22 7JJ

Group England

Haynes Publications, 861 Lawrence Drive Newbury Park California 91320 USA

Inc

Acknowledgements [hanks are due to the Champion Sparking Plug Company Limited, who supplied the illustrations showing the spark plug conditions, and o Duckhams Oils, who provided lubrication data. Certain illustrations re the copyright of Mercedes-Benz (United Kingdom) Limited, and re used with their permission. Thanks are also due to Sykes-Pickavant _imited who provided some of the workshop tools, and to all those yeople at Sparkford who helped in the production of this manual.

€) Haynes

Publishing Group 1988

\ Book in the Haynes Owners Workshop

Manual

Series

>rinted by J. H. Haynes & Co. Ltd., Sparkford, Nr Yeovil Somerset BA22 7JJ, England

All rights reserved. No part of this book may be reproduced or ‘ransmitted in any form ar by any means, electronic or nechanical, including photocopying, recording or by any nformation storage or retrieval system, without permission n writing from the copyright holder.

SBN 0 85696 928 1

3ritish Library Cataloguing in Publication Data Viead, John S. 7950Mercedes-Benz 190 owners workshop manual. 1. Cars. Maintenance & repair — Amateurs’ manuals } |. Title Il. Series 629.28'722 ISBN 0-85696-928-1

Nhilst every care is taken to ensure that the information in his manual is correct, no liability can be accepted by the juthors or publishers for loss, damage or injury caused by any rrors in, or omissions from, the information given.

Contents Introductory pages About this manual Introduction to the Mercedes-Benz 190 General dimensions, weights and capacities Jacking, towing and wheel changing Buying spare parts and vehicle identification numbers General repair procedures Tools and working facilities Safety first! Routine maintenance Recommended lubricants and fluids

Conversion factors Fault diagnosis

5 3 6 7 8 9

10 12 13 18 19 20

Chapter 1 Engine

23

Chapter 2 Cooling system

53

Chapter 3 Fuel and exhaust systems

63

Chapter 4 Ignition system

: 93

Chapter 5 Clutch

102

Chapter 6 Manual gearbox and automatic transmission

110

Chapter 7 Propeller shaft

134

Chapter 8 Final drive and driveshafts

140

Chapter 9 Braking system

147

Chapter 10

Suspension and Steering

167

Chapter 11 Bodywork

201

Chapter 12 Electrical system

230

Index

266

OGL Zueg-sepedia

>

Lie

About

this manual

Its aim The aim of this manual is to help you get the best value from your vehicle. It can do so in several ways. It can help you decide what work must be done (even should you choose to get it done by a garage), provide information on routine maintenance and servicing, and give a logical course of action and diagnosis when random faults occur. However, it is hoped that you will use the manual by tackling the work yourself. On simpler jobs it may even be quicker than booking the car into a garage and going there twice, to leave and collect it. Perhaps most important, a lot of money can be saved by avoiding the costs a garage must charge to cover its labour and overheads. The manual has drawings and descriptions to show the function of the various components so that their layout can be understood. Then the tasks are described and photographed in a step-by-step sequence so that even a novice can do the work.

/ts arrangement The manual is divided into twelve Chapters, each covering a logical sub-division of the vehicle. The Chapters are each divided into

Sections, numbered with single figures, eg 5; and the Sections into paragraphs (or sub-sections), with decimal numbers following on from the Section they are in, eg 5.1, 5.2, 5.3 etc. It is freely illustrated, especially in those parts where there is a detailed sequence of operations-to be carried out. There are two forms of illustration: figures and photographs. The figures are numbered in

Introduction innovative

new

model

heralded

a departure

from

traditional

Mercedes thinking, and marked the first venture into the medium-sized saloon market by one of the world’s most respected manufacturers of large quality cars. All cars feature

There is an alphabetical index at the back of the manual as well as a contents list at the front. Each Chapter is also preceded by its own individual contents list. References to the ‘left’ or ‘right’ of the vehicle are in the sense of a person in the driver's seat facing forwards. Unless otherwise stated, nuts and bolts are removed by turning anti-clockwise, and tightened by turning clockwise. Vehicle manufacturers continually make changes to specifications and recommendations, and these, when notified, are incorporated into our manuals at the earliest opportunity. Whilst every care is taken to ensure that the information in this manual is correct, no liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given.

Project vehicles The main project vehicle used in the preparation of this manual, and appearing in many of the photographic sequences was a 1985 Mercedes-Benz 190. Additional work was carried out and photographed on Mercedes-Benz 190E models with both manual and automatic transmission.

to the Mercedes-Benz

The Mercedes-Benz 190 was launched in Europe at the end of 1982, and introduced into the UK in September of the following year. The

sequence with decimal numbers, according to their position in the Chapter — eg Fig. 6.4 is the fourth drawing/illustration in Chapter 6. Photographs carry the same number (either individually or in related groups) as the Section or sub-section to which they relate.

traditional, solid, practical Mercedes design and engineering, with new advances in automotive technology, foremost amongst these being the meticulous attention to ride quality and handling. This has been achieved by further refining the proven MacPherson strut front suspension arrangement, used extensively by other manufacturers but not previously by Mercedes, and combining

190

this with a new multi-link independent rear suspension. The model range is not extensive, offering just one body style, but with a choice of engines and options to enhance the package. The cars covered by this manual are all four door saloons powered by a 1997 cc four cylinder overhead camshaft engine, with carburettor induction on 190 models, or electronic fuel injection on 190 E models. The engine is mounted longitudinally, and drives the rear wheels through a five-speed manual gearbox, or four-speed automatic transmission. Full instrumentation is provided, together with power steering and central locking, and additional options which include electric windows, electric sunroof and air conditioning.

General dimensions, weights and capacities Dimensions COMGTENTY TET Le nancteece sno conceccrtcce neo rae Rtas oon DEE CSD Ae Ee cneeee eeEeee OVE ral lRWiGtNiece coeeeese noc create Seas nce tee erence vette set vareccnestsiescvirs

4420 mm 1678 mm

(174.1 in) (66.1 in)

Overallbmeichit cce te ccc acsz csctce rcotees eee reese cen eee a aoe oe vee ee nyc bets WV Neel base ersten cree tee cae acct Sec erce Mo tecec Pattee sect Mic snrecs tine see cass cespadonte FEOM Bg ha Cte crece cectseeeae ete cte aa see seotc saesenecs sev shee eee teeas ten ceeencars Masene Mies sexes RE arateKae ace er ences cxscceece Se svacee sec cecscsus ceihaterccatestersseusactesstesscusatee seciviee sascueevs

1390 2665 1437 1418

mm mm

(54.8 in) (105.0 in)

mm mm

(56.6 in) (55.9 in)

Weights Kerb weight:

NG Oreceseses se Sense cee tas ia ses ecasiarcer ees vitae cutee seeee eee Cee acon NSO} 3.Soca Pusan ceceeer CR cee te a een rece CSO

ses cus sates ca REE

1130 kg (2491.7 Ib) 1140 kg (2513.7 Ib)

Gross vehicle weight:

UO Werese MRR Ns cect RBs ys ouctOoacs ew taseacenc an Mee tenon cma ae ch esse t os 9 GVDO pee as Reese are os Seto ott ogSe RES Te Sew tar teeta sce ee eae o Ta ea USS Maximumimoof racks Oa ssceesscaccse-oncneteeeceet tae creer etree seafecane 7 0Sgr/bt 4——

hi i

a *>]

es!

es

aq—

0 Sgrignvs

st >zt—0

OSbiittws: Sprit

rsp OSD JOS

oF

blir

+>—+- OSblign aT

2 pi: e3

E

o

H ea etesain

e7 e6!

a

++

o

fo)

ot}

A—

ier St 0590 —0.Sws/bi

P05

b

+

~ Ee 4+ ++

i

+= =
—+-0,75qn/ge & = =

| |

We lk LE wi‘a

Bi zt

a

ewe

|

:

f

arti

+

t07Sbl/gr

¢

te th ee ty hal

| Libr/blyn

f

|

ire #53If rr)

[orsswirt

ep

= i— ———

07Sws

=

t

|

||

la

Od

wy

)

Bi3

tO

-

>

= 0759

1|

fbn

*

ee

tad, TARP RAZ,4 =

Elele2e3e4 :

2-075 gr/ws—

e5_

$27/2 g

I

Fig. 12.15 Wiring diagram for 190 E models

G

T

$

up to chassis number

K12 |

000 001-045 803

$29/1 6

B2 |

7

{

261

§ s

$24

ae

—

12

¥

E91

Pet

wi

wit

0 =

=o! ||! 6 | a8

=e

i

17/9

f— 05qr/b| —

|

a :

See

_

a

G4 Feit be imncae lair ew

3

:

E15/3

=

|

att

_

aca

ry 21 re

v1

a

=

K4 [ 3

ince

=

{

ee eos

eee

l

$200

|

12

S213

f

| —

1

$17/5

iy

Ean

& Wied

BGley

ys

2} ral

—-$17/6

os ae

W707Sbr ————+-«

ae

!

F4@1

GS

|e1

|_|

Sum aa le: e3 i je4

wit |

4

te ae

075ge

ee

i

nasY12

ae

£3

= ee

{

a O75qrirt see

| ||

i=

see

F

a

(X71

|

sl

8 M10/3

25rt/ws:

: bat

+i

-

HS

——

eeulieeal

pen

ce

he

é a

= ol [at si XS/1

{34 Ls}

palais

eal

g 3 |

‘5,

Ce

hal eo :

w

1

AStt

25rtiws

fal $17/7

& t5 Pres Ww

2Srtige

wi

13| W

“

i

enae

523 a Se

53 | ae

&

n

S20msiaess

|

is

‘ilmesia

aE

=i)

ne

‘st

|

eeGd

I

10

s2

|

z!

== @ | |Toe,

c

eee

$19

} x13 rasfod |

_&

Exigahed

|

7

$214

mA

ar

eet

2 an ‘

° a $O7Sbrigh

O7Sqn/blJ

_

_R3iP

iM

9

:

It | (eee

ig A wleeel

13/1 /

2

sé

I

Be

|

- a [

8

ED/1

|

S

ie

2!

(iar Medan

=

al

E9/1

AAA fo aeea ae

aie

O75bi/sw

E9/1

fe a 4h Ee

BES, Tat |

Ale

E9/1

wwres 8 E19/1 J

oasrtiws

‘

075qr/gn

>—+25vi/ws—>

25vilws:

—

2.5 vilws

a

D

Cc a

07S swign

on

{

{

|

———};—++-

4

+++

-

[

i

|

e-

i T

caret

HL.

Sr

i

Foes

ny|

tat

|

K1

|

see

ey 4

ah

WS) mp) —= -

O759n =075ws —

== =

SS

aa

{eubseiih

O7Sbr/bI

ae

| wo Jow/bign

iY

Bi3

i tet

:

i Ht

w9 3

|

25rt

|

07561 — or ae ; ONEswirt Ws

of

Ma

Eat

Y14

pike

=

L2 aes :

$40

Ys

et bs

|N

Cl os),F39n

S, Si

et

[Lae ay

a

FFs HHY

caiaiee fica &

ileal

eee

& &

3

ie

x

ee

i

y

plulial|

a

|

$7,

m1tr

|

$10/1

O7Sqn/ge

2

S255

G

3

z

8

22 eeMe Boe

i

"ee

5

2

Ae

SL rt

So

1srtisw

Cee a

075sw/rt

190

”

4w3

-

O7Squt+

fost 07Sbr/sw

al

34 —075 brit 4W10

")

a+ 075sw

|

af as

we

S=+-075ct r]

wo

Wo

|| 5

5

sre

a

‘

ets fede

I

Elele2e3e4

thie

W3

|

ra a

al (a

|

=>

R4 hy Be Bia

RE) r

ge

5B

OrSqrvg g vas

eu =

e5

N1/1

5

2

3

Tt

hE $5/2

rez

=

gr

3

pga

Bese

hannai Gone

see

£53

—

075qn

[ |

I) AER ‘is

=ttee ie

ea pd

|ao

| |

o7srs/bl

eo

—

arbas |

pat

(TU

Pines

:

R

H

0752s —

$27/2

I

FA

(ex $29/1

5

I

6

es

B2

=n

Fig. 12.16 Wiring diagram for 190 E models from chassis number 1A 000 001-153 269 or 1F 000 001-050 579

ee

ae

263 a

a

7

E91

E9/1

|

E9/1

| [el

E9/1

thal

Lt

3

[

$21/4

al

SORA ]

iG =E9/1

S19

0

s2

[

:

Si

al

I

$20 _ s1

s3

"

l

s2a

$21/3

=

2

|

|

-

a

ee

a

te

A

wis

=

==

=

Et 5

Sidse

1

ayy.

esr

a2

=o

=| «|

:

1

$18

me

Fd 5

a . es

ai

cigll

21

owTt ae Oe F 7st KI-[

pe

a

een Bee

i

.

a

:

at wal SL

a

Cea

le

an

Ee

fo

ppp

la

ee

enn

ee

tt

ie

hai

ee

pty

Rm

wi

M10/3

25rtlws

WIE 075br

4

a

B ETS

Y12

a

eee

:

i: E19/2

x

O75br/Wreeglcsbeers es

e3

je4

eae

(Se

ee

e2

4

ix71

8

M10/5

—_

ane

= Os ee

WwW

O7Sqrtt

CS En Bese ss |

ees

!

(ae

|

)75qrvi

eee

| iB |

_SS

oS

b 1

n

| |

2s |

=

T

ll i

ge 55

075g¢ ,

a

yifif

075s

‘| H

st

si7k

rad 5&

Ihe

| Eixen

F

_

a ie

i

a

4

|

Ae

t

+

sivis

s

Se

Y

(ess |

25th

‘

[nf

5 a |ang al

25rtmge—+—

$17/7

eee

ABS DE RS

a

(Le sors

'

gSe 8

Oe

al

z

M

nat.

oe

[a _ 3

l

1]

gl yt

3338 1 *

i

|

O7SbI

yea)

aoe 5 nal $345 Case Jt

A

8

ama! bid

&

Sree

u

|

|

3)

wiles

ave

075b1

|

slot

(pe

Sele

erga

x13

Dremel

@ | |

rn

ie

S

Oey

ie

r ve

i

E

O7Sprigr 7

%

ay

=

os €) |

|

5

§

5 i

|

=

Bai is 5 as (®aT eicalinal 13/1

2

ats

=

———— ‘ Ss Cm7/9 Pal

A

a

3 E19/1

=

table Sok 72] an

us

o7Sar ae

|

$16/1

da B

ane

E ILLS

il Sa ae

oe

=

O75swh

=

(ae

!

ee

! 1s

|

2

075rt/gews

=

psa

a

|

Bap

aie

as

il

ee

| yeZ|

Yspe

|S

Ng

eli.

oaees

ee pe

eee KB.

“i

:
—t— 25rtiws

ifaiien Ss

|

Iswitt vi

eee

4

=

=F

f]

=

|E18

se)

be2

+

=

oe osbe Es

OSbl/ws

=

See

Be RR

BA ed

j

A DID Sa

2

oe

si R21

OrSberot

A

1,

atl ||

ie

be

oz

4

!

aes

ib, 1540-13411

$26 201540 1200

5

=a

|

aie,

I

8

I

9

0

i

2

Fig. 12.16 Wiring diagram for 190 E models from chassis number 1A 000 153-269 999 or 1F 000 001-050 579 (continued)

264

Key to Figs. 12.15 and 12.16 Not all items are fitted to all models

Location

Component Instrument cluster Indicator warning, left

Al

Indicator warning, right Main beam warning Fuel reserve warning Charge indicator Brake pad wear indicator Brake fluid/handbrake

indicator

Instrument lighting Warning buzzer Indicator warning, acoustic

Instrument lighting rheostat Coolant temperature gauge Fuel gauge Clock/Tachometer Radio Air volume meter sensor Fuel gauge sensor

Temperature sensor, evaporator Coolant temperature sensor, KE Coolant temperature sensor, gauge Headlamp unit, left Main beam

E2

Dipped beam Sidelamp Foglamp Indicator Headlamp unit, right Main beam Dipped beam

Sidelamp Foglamp

ES

E4

Indicator Rear lamp unit, left Indicator Tail/parking lamp Reversing lamp Brake lamp

Rear foglamp Rear lamp unit, right Indicator Tail/parking lamp Reversing lamp Brake lamp Heater control lighting Glovebox lamp Interior lamp, front Interior lamp, rear Boot lamp

Number plate lamp, left Number plate lamp, right Central electrics unit Battery

Alternator and regulator Dual-tone horns Overvoltage protection relay Headlamp cleaning relay

Component K4 Electric window relay K8 Relay for auxiliary fan/engine fan K12 ‘Tempomat'’ deceleration relay L1 TDC sensor L2 Road speed sensor

M1 M2 M3 M4 M5/1 M5/2 M6/1 M6/2 M6/3 M10/3 M10/4 M10/5 M10/6 M11 M12/1 M16 N1/1 N4 N5/1.— N10

Starter motor

Blower motor Fuel pump Auxiliary fan Washer pump Headlamp washer pump Wiper motor Wiper motor, headlamp, left Wiper motor, headlamp, right Window lift motor, front left Window lift motor, front right Window lift motor, rear left Window lift motor, rear right Electric aerial Sunroof motor Actuator, ‘Tempomat' Electronic ignition switching unit Control unit, ‘Tempomat’ Fuel pump relay Combination relay — indicators, heated rear window, wiper motor N19 Air conditioning control unit R1 Heated rear window R2/1 Washer nozzle heater R3 Cigar lighter/front ashtray lighting R4 Spark plugs R14 Blower motor ballast resistor R21 Auxiliary air valve heater coil S1 Rotary light switch $2/1 Ignition starter switch $3 Air volume switch S4 Combination switch s1_ Indicator switch s2 Headlamp flasher switch s3. Dimmer switch s4 Washer switch s5 Wiper speed switch s5 | Intermittent wipe s5 Il Slow wipe s5 Ill Fast wipe $5/2 Ignition distributor S6 Hazard flasher switch S7 Horn contact $8/1 —_ Lights-on buzzer contact S9 Stop-lamp switch $10/1 Brake pad wear contact, front left $10/2 Brake pad wear contact, front right Sint Brake fluid indicator switch Sy Handbrake indicator switch $13/1 Electric sunroof switch $14 Heated rear window switch $16/1 Starter interlock/reversing light switch

Location

8C

265

Key to Figs. 12.15 and 12.16 (continued) Not all items are fitted to all models

Component $17/3 Door switch, front left $17/4 Door switch, front right $17/5 Door switch, rear left S$17/6 Door switch, rear right Door switch, comfort circuit, left $17/7 $17/9 Glovebox lamp switch $18 Rear interior lamp switch Sig Switch group, electric windows, right $1 Window switch, front right $2 Window switch, rear right $20 Switch group, electric windows, left Window switch, front left $1 s2 s3 $21/3 $21/4 $24 $25/1 $26 $27/2 $29/1 $30 $31 $32 $40 T1 V1

Window

switch, rear left

Safety switch, rear electric windows Window

switch, rear left

Window

switch, rear right

Fresh/recirculated air switch Temperature switch, 100°C Thermotime switch Deceleration microswitch Throttle valve switch, full load Kickdown switch

Refrigerant compressor switch Auxiliary fan switch ‘Tempomat

switch

Ignition coil Comfort circuit diode

Location

Component

4A 4A 10B 10B 6B 6B 9B 9A 10A 9A 10A 10A 11A 11A 12A 9A 6A 6G 8H/9H 5H 6H 12E 9G 9G 10G 4G 7C

Ww1 W2 W3 W4 W5 W6 W7 wg W10 X5/1 x6 X11 K13 K14 X33 X35 AT1 Y1 Y2 Y3 Y5 Ye Y12 Xt3 Y14

Colour codes

bl

gn

Blue brown Ivory Yellow Green

nf rs rt Sw vi

Pink Red Black Purple

gor

Grey

ws

White

br el ge

Neutral

Wire codes Example: Wire code 1.5 gr/rt

Basic colour — grey Tracer colour — red Cross-sectional area of wire

=

Location

Main earth (behind instruments) Earth, front right (near lamp unit) Earth, front left wheel arch (igntion coil) Earth, front interior lamp Earth, engine Earth, boot wheel arch, left Earth, boot wheel arch, right Earth, front left (near lamp unit) Earth, battery Interior cable connector 1C/9C/11G Cable connector 6B Diagnostic socket 1C/3H Cigar lighter connection 7B Plug connection 9H Plug connection, KE/’Tempomat’ 5H Cable connector, battery 10G Plug connection, switchover valve idle speed stabilisation 10C Electrohydraulic actuator 6G Engine fan solenoid 6G Switchover valve, automatic transmission 12D Refrigerant compressor solenoid 9G Starting valve 9H Switchover valve, idle speed increase 10C Switchover valve, fresh/recirculated air flap 5A Switchover valve, idle speed stabilisation 8G

1.5 mm?

Index A

B

About this manual — 5 Accelerator cable removal and refitting carburettor models — 70 fuel injected models — 70, 83 Accelerator cable and linkage adjustment carburettor models — 69 fuel injected models — 82 Air cleaner and element removal and refitting carburettor models — 64 fuel injected models — 81 Air cleaner automatic air temperature control description and testing — 64 Air conditioning refrigerant compressor drivebelt removal, refitting and adjustment — 229 Air conditioning system precautions and maintenance — 228 Alternator fault tracing and rectification — 234 removal and reftitting — 233 Alternator brushes and regulator renewal — 234 Alternator drivebelt removal, refitting and adjustment — 232 Antifreeze mixture — 57 Anti-lock braking system components removal and refitting electronic control unit — 164, 165 front wheel speed sensors — 165 hydraulic modulator — 164 rear wheel speed sensor — 165 description and operation — 163 precautions — 164 Anti-roll bar removal and refitting front — 181 rear — 190 Automatic transmission description — 111 fault diagnosis — 133 gear selector lever assembly — 131 gear selector rod — 130 maintenance and inspection — 128 removal and refitting — 131 specifications — 110, 111 starter inhibitor switch — 129 torque wrench settings — 111 Automatic transmission fluid

Balljoint dust covers renewal — 181 Balljoint, wishbone removal and refitting — 180 Battery charging — 232 removal and refitting — 231 Bleeding brakes — 162 clutch — 108 Bodywork — 201 et seq Bodywork description — 201 maintenance bodywork and underframe — 201 routine — 13 schedules — 15 upholstery and carpets — 202 major body damage repair — 203 minor body damage repair — 202 Bonnet adjustment — 205 hinge removal and refitting — 208 lock removal and reftting — 208 release cable removal and refitting — 208 removal and refitting — 203 support strut removal and refitting — 208

draining and refilling — 128

Boot lid lock removal and refitting — 208 removal and refitting — 208

Brake disc inspection, removal and refitting front — 152 rear — 155

Brake light switch adjustment, removal and refitting — 159 Brake pedal removal and refitting — 108, 159 Braking system — 147 et seq Braking system anti-lock — 163, 164 description — 148 fault diagnosis — 166 hydraulic system (bleeding) — 162 maintenance and inspection — 148 specifications — 147, 148 torque wrench settings — 148

Bulbs renewal exterior lamps — 242 interior lamps — 242, 244

Index

267

ee

Bumpers (front and rear) dismantling and reassembly — 209 removal and refitting — 209

Cc Camshaft removal and refitting — 25 Camshaft and rocker arms examination and renovation — 50 Capacities, general — 6 Carburettor automatic choke adjustment — 73 dismantling and reassembly — 76 dismantling and reassembly — 73 idle speed and mixture adjustment — 72 removal and refitting — 71 Central electrics unit removal and refitting — 238 Central locking system vacuum pump removal and refitting — 221 Centre console removal and refitting — 221 Centre console switch removal and refitting — 240 Clutch — 102 et seq Clutch description — 102 fault diagnosis — 109 hydraulic system (bleeding) — 108 specifications — 102

torque wrench settings — 102 Clutch assembly removal, inspection and refitting — 106 Clutch driven plate assessment of wear — 105 Clutch

pedal

removal and refitting — 108 Clutch release bearing removal, inspection and refitting — 107 Coil (ignition) testing, removal and refitting — 100 Connecting rod and piston assemblies examination and renovation — 48 removal and refitting — 46 Control pressure cable adjustment carburettor engines — 129

fuel injected engines — 129 Conversion factors — 19 Coolant level indicator description and testing — 61 Coolant pump removal and refitting — 60 Cooling fan and fan coupling (electromagnetic) — 59 Cooling system — 53 et seq Cooling system description — 54 draining — 56 fault diagnosis — 62

filling — 57 flushing — 56 maintenance and inspection — 55 specifications — 53 torque wrench settings — 53 Crankshaft removal and refitting — 46

Crankshaft, main and big-end examination and renovation — Cylinder block and crankcase examination and renovation — Cylinder head dismantling and reassembly —

bearings 48 48

34

removal and refitting carburettor engines — 30 fuel injection engines — 33 Cylinder head and pistons decarbonising — 50 Cylinder head and valves examination and renevation — 50

D Differential assembly (final drive) drive flange oil seal removal and refitting — 142 removal and refitting — 141 Dimensions — 6 Disc calipers (front) overhaul — 150 removal and refitting — 150 Disc caliper (rear) overhaul — 154 removal and refitting — 153 Disc pads inspection and renewal front — 148 rear — 152 Distributor removal and refitting — 95 vacuum unit — 96 Door courtesy light switch removal and refitting — 240 Door exterior handle removal and refitting front — 216 rear — 218 Door inner trim panel removal and refitting — 212 Door lock removal and refitting front — 216 rear — 218 Door lock solenoid (central locking system) removal and refitting — 218 Doors (front and rear) removal and refitting — 218 Driveshaft constant velocity joint rubber boots removal and refitting — 144 inner constant velocity joint dismantling, inspection and reassembly — 145 removal and refitting — 143 Electrical system — 230 et seq Electrical system description — 231 fault diagnosis — 252 maintenance and inspection — 231 precautions — 231 specifications — 230 torque wrench settings — 230 Electromagnetic fan and fan coupling removal and refitting — 59 Engine — 23 et seq Engine description — 26 examination and renovation — 48 fault diagnosis — 51 maintenance and inspection — 26 major operations possible with engine in car — 27 major operations requiring engine removal — 27

method of removal — 38 removal and refitting — 38 separation from and attachment to transmission — 39 specifications — 23 to 25 torque wrench settings — 25 to 26 Engine mountings removal and refitting — 36

268 Exhaust system

checking, removal and refitting — 79, 91

F

Facia removal and refitting — 224 Facia and central console switches removal and refitting — 239 Fault diagnosis — 20 et seq Fault diagnosis braking system — 166 clutch — 109 cooling system — 62 electrical system — 252 engine — 51 exhaust system — 92 final drive and driveshafts — 146 fuel and exhaust system — 92 ignition system — 101 manual gearbox and automatic transmission — 133 propeller shaft — 139 suspension and steering — 199 Final drive and driveshafts — 140 et seq Final drive and driveshafts description — 140 fault diagnosis — 146 maintenance and inspection — 141 specifications — 140 torque wrench settings — 140 Flywheel or torque converter driveplate examination and renovation — 50 removal and refitting — 44 Fuel and exhaust systems — 63 et seq Fuel gauge sender unit (carburettor and fuel injected model: removal and refitting — 69 Fuel pump removal and refitting carburettor models — 67 fuel injected models — 86 Fuel system (Part A: carburettor models) description — 64 fault diagnosis — 92 maintenance and inspection — 64 specifications — 63 to 64 torque wrench settings — 64 Fuel system (Part B: fuel injected models) airflow sensor — 89 auxiliary air device — 90

cold start valve — 88 description and operation — 81, 83 electro magnetic pressure actuator — 90 fault diagnosis — 92 fuel accumulator — 86 fuel distributor — 88 fuel filter — 86 fuel injection control module — 90

fuel injectors — 86 fuel pressure regulator — 89 idle speed and mixture adjustment — 86 maintenance and inspection — 81 precautions and general repair information — 83 specifications — 64 throttle valve housing — 90 torque wrench settings — 64

Fuel tank (carburettor and fuel injected models) removal and refitting — 67 Fuses and relays, general — 237

G Gearbox casing and rear cover (manual) dismantling and reassembly — 120

Index Gearbox (manual) dismantling into major assemblies — 114 overhaul general notes and precautions — 113 reassembly — 122 removal and refitting — 112 Gear lever and remote control assembly

(manual)

removal and refitting — 127 Gear selection lever assembly (automatic transmission) removal and refitting — 131 Gear selector rod (automatic transmission)

adjustment — 130 Gearshift linkage (manual) adjustment — 126

; Gears, synchro units and shift mechanism inspection and overhaul — 121 Glovebox removal and refitting — 224

H Handbrake adjustment — 156 Handbrake cables removal and refitting — 159 Handbrake lever removal and refitting — 157 Handbrake shoes removal and refitting — 156 Headlamp alignment — 246 Headlamp glass removal and refitting — 244 Headlamp height adjustment system — 246 Headlamp switch removal and refitting — 240 Heater removal and refitting blower motor — 228 matrix — 228 valve — 228 unit — 227 Horns removal and refitting — 250 HT leads — 100 Hub and bearings (front) removal and refitting — 172 Hub bearings (front) adjustment — 173 Hub bearings (rear) removal and refitting — 183 Hub carrier (rear) removal and refitting — 182 Hydraulic brake pipes and hoses removal and refitting — 162 Hydraulic system bleeding brakes — 162 clutch — 108

Ignition switch removal and refitting — 239 Ignition system — 93 et seq Ignition system description — 94 fault diagnosis — 101 maintenance and inspection — 94 precautions — 95 specifications — 93 testing — 97

torque wrench setting — 93 Introduction — 5

(manual)

269

Index

O

Instrument panel components removal and refitting — 240 removal and refitting — 240

Oil filter housing removal and refitting — 36 Oil pump dismantling and reassembly — 44

J

examination and renovation — 49 Oil seals and gaskets examination and renovation — 50

Jacking — 7

P

if Lamps (exterior) removal and refitting front direction indicator lamp — 244 headlamp unit — 244 rear lamp cluster — 244 Layshaft dismantling and reassembly — 120

Lubricants and fluids (recommended)

— 18

Lubrication system, description — 36

M Mainshaft

dismantling and reassembly — 117 Maintenance, routine — 13 to 17 Manifold (carburettor models)

Piston and connecting rod assemblies examination and renovation — 48 removal and refitting — 46 Pistons and cylinder head decarbonising — 50 Propeller shaft — 134 et seq Propeller shaft centre support bearing removal and refitting — 138 centering sleeves removal and refitting — 139 description — 134 fault diagnosis — 139 flexible rubber couplings and vibration damper removal and refitting — 137 maintenance and inspection — 136 removal and refitting — 136 specifications — 134 torque wrench settings — 134

inlet pre-heater removal and refitting — 78

removal and refitting — 79

Q

exhaust

removal and refitting — 79 Manifold (fuel injected models)

Quarterlight (rear door fixed) removal and refitting — 216

inlet

removal and refitting — 91 exhaust

removal and refitting — 91 Manual gearbox and automatic Manual gearbox description — 111 fault diagnosis — 133

transmission — 110 et seq

gearbox — 112 to 114, 122 gearbox casing and rear cover — 120 gear lever and remote control assembly — 127 gears, synchro units and shift mechanism — 121 gearshift linkage — 126 input shaft —- 118 intermediate plate — 120 layshaft — 120 mainshaft — 117 maintenance and inspection — 111 specifications — 110

torque wrench settings — 110 Master cylinder (brakes) overhaul — 160 removal and refitting — 160 Master cylinder (clutch) overhaul — 103 removal and refitting — 102 Mercedes star removal and refitting — 208 Mirror assembly, driver’s door removal and refitting electrically operated — 218 manual mirror — 218 Mirror glass, driver’s door renewal electrically operated — 218 manual

mirror — 218

R Radiator removal, inspection, cleaning and refitting — 57 Radiator grille removal and refitting — 208 Radio aerial removal and refitting — 252 Radio/cassette player removal and refitting — 251 Repair procedures, general -— 9 Routine maintenance see Maintenance, routine

S Safety precautions — 12

Seat belts removal and refitting — 221 Seat, rear removal and refitting — 221 Seats, front ; removal and refitting — 220 Shock absorber (rear) removal and refitting — 189 Slave cylinder (clutch) overhaul — 104 removal and refitting — 103 Spanner jaw gap comparison Spare parts, buying — 8

table — 11

270

foie

SET

nw See

Index eee

Spark plugs and HT leads, generai — 100 Speakers (front and rear) removal and refitting — 251 Speedometer cable removal and refitting — 241

Starter inhibitor switch

:

removal, refitting and adjustment — 129 Starter motor overhaul — 224 removal and refitting — 234 Steering damper removal

and refitting — 196

drag link removal and refitting — 197 idler arm assembly — 198 maintenance and inspection — 171 power steering gear removal and refitting — 194 pump drivebelt removal, refitting and adjustment — 196

pump (October 1984 models on) removal and refitting — 19£ pump (pre-October 1984 ma@dels) removal and refitting — 19 track rod removal and refitting — 197 specifications — 167, 168 torque wrench settings — 168 Steering column dismantling and reassembly — 192 removal and refitting — 191 combination switch removal and refitting — 239

Steering lock removal and refitting — 193

Steering wheel removal and refitting — 191 Sump removal and refitting — 40 Sunroof, general — 221 Suspension and steering — 167 et seq Suspension and steering description — 168 fault diagnosis — 199 Suspension (front) front wishbone removal and refitting — 179 mainenance and inspection — 170 road spring (front) removal and refitting — 178 specifications — 167 steering knuckle removal and refitting — 175 strut removal and refitting — 177 torque wrench settings — 168 wishbone balljoint removal and refitting — 180

wishbone (front) removal and refitting — 179 wishbone mounting bushes renewal — 179 Suspension (rear) camber strut removal and refitting — 184 maintenance and inspection — 170, 171 pulling strut removal and refitting — 185 pushing strut removal and refitting — 186 rear road spring removal and refitting — 189 rear track rod removal and refitting — 186 specifications — 167

spring support arm removal and refitting — 188 torque wrench settings — 168

Switches — 239, 240

T Tappets,

hydraulic

description, removal and refitting — 28 Thermostat removal, testing and refitting — 58

Thermostat housing removal and refitting — 59 Timing chain renewal — 35 Timing chain components and intermediate shaft removal and refitting — 42 Timing cover removal and refitting — 40 Timing cover, gears, chain and intermediate shaft examination and renovation — 49 Timing (ignition) adjustment — 96 Tools, general — 10 Torque converter driveplate removal and refitting — 44 Towing — 7

V Vacuum servo unit — 162 Valve clearances

adjustment — 27 Valves examination and renovation — 50 Vehicle identification numbers — 8

Ww Weights - 6 Wheel alignment

(front and rear) and steering angles — 198 Wheel changing -— 7 Wheels and tyres general care and maintenance — 199 Window glass removal and refitting front door — 214 rear door — 216 Window regulator removal and refitting front door — 213 rear door — 215 Windscreen and rear window

removal and refitting — 218 Windscreen

washer system

removal, refitting and adjustment — 249 Windscreen wiper blades and arms removal and refitting — 246 Windscreen wiper motor removal and refitting — 249 Windscreen wiper motor and linkage removal and refitting — 247 Wiring diagrams — 254 to 265 Working facilities — 10

a d ay) 29" . ip we!MoSh i ahi £¥ Sebmatt 7

ae

4s)"

ewemy

o

» ‘okie

“a

>

2

ain

& i.

ry

{ON - » royals

ne

‘el

@itt«

wie.

3G

Wa5

8!

rée

> 2a0

€

gctre

ave

Lad

fitting Bad a biee ps

Pen

ae

Sr.

weealver

en

wie ;

he

vats

oe

oe

Nir

Lil

4!

roe

_s 4

Wir*

rR)

oa

¥ err

ow

.

oS

Gist

Dri

wleeiag

Ging

wed

ae.

Emay mgt peo

~Re7

dhe yanLAA bn Let

NiPine Werking tougiitias a

=

”

:

Are SNhuagt Sn) ¥ wipe Wolo @ef adres

ae iy alee

oy ~_

.

>see

:

-

Models covered by this manual Mercedes-Benz 190 & 190 E 1997 cc petrol engine Does not cover Diesel engine, 190 E 2:3-16 or 190 E 2.6 models

The clear, step-by-step illustrated instructions cover the dismantling, inspection, repair and refitting of the engine, cooling system, fuel and

emission gearbox,

control systems,

exhaust, ignition system, clutch, manual

propeller shaft or drive shafts, braking system,

electrical system,

suspension, steering, bodywork and fittings. Routine maintenance, complete specifications and detailed fault diagnosis procedures are also included. For rear axle differential units and automatic transmissions (where applicable) the removal, refitting and fault diagnosis procedures only are covered. ONLY HAYNES COMPLETELY STRIP AND REBUILD THE CAR FOR EACH MANUAL

‘These are really worthwhile manuals which can save you a lot of money. Autocar

‘Haynes manuals are outstanding for giving the learner mechanic an easy to follow guide to doing most any type of repair on maintenance work on his or her car.’ Road & Track ‘These authentic manuals are actually written from practical experience ...’ Car Mechanics

Whether you just want to change your oil or replace your plugs, or change your clutch or rebuild your gearbox, the Haynes manual will show you how,

and can

help you save

pounds

on servicing and repair bills.

‘Excellent value for money, beginners and experts should find it equally useful, overall a mine of information.’ Motor ‘It is thus opportune that a simply splendid Owners Workshop Manual has just come

A Haynes manual can help you stretch your motoring budget that little bit further in other ways too. Regular maintenance and servicing will mean your car is safer to drive whilst giving you more of those precious mpg. What's more, a car that is well looked after will hold its price better and last a lot longer!

H 923103

ISBN

0 85696 928 1

HAYNES MANUALS EXPLAIN BEST GO BY THE BOOK

out.

Every

imaginable job is illustrated Autosport

...’

‘For the home mechanic Haynes DIY workshop manuals show clearly step-by-step service operations in pictures.’ Sunday Mirror

PF €6E-L

T