Mercedes Benz Classics: Owners Operation, Service, and Repair Workshop Manuals

Mercedes M102 Engine Service Manual

The Mercedes Benz 1.8 2.5 Liter M102 Engine, Produced: 1980 to 1996


Download: Mercedes Benz M102 E 2.3 Engine Service Manual

Mercedes  M102 Engine Service Repair ManualMercedes M102 E 2.3 Engine Manual
Download: 80.2mb, 843 pages, .pdf
Applications: W123 W124, W201, W460, W461, W463, etc.

Delivery By Download Link:

Sent to your PayPal email address: $19.95


Mercedes Benz M102 EngineThe M102 engine family was a straight-4 gasoline automobile engine from Mercedes-Benz in the 1980s and early 1990s. It is a relatively oversquare engine with a large bore and short stroke compare to the M115 engine which was used during the same time frame.

The M102 engine came out to replace the old M115 engine in 1980. This four cylinders engine was built entirely from scratch. It had new cast iron cylinder block, aluminum 8-valve cylinder head with one camshaft.

In 1984 engine got new light connecting rods and crankshaft as well as hydraulic tappets/lifters and the new style oil filter. The 2.0 L M102 from the beginning had the single-strand timing chain that was very unreliable, in 1987 this chain was replaced by a more durable double-row chain.

Together with the M102 inline four-cylinder engine, Mercedes produced the inline M103 3.0L six-cylinder engine.

Mercedes M102 Engine Application Survey

Mercedes M102 Service Repair Manual

Production of the M102 engine ended in 1994 when Mercedes started producing the new 2.0-liter M111 engine for their cars.

Mercedes Benz M102 Engine

M102 Engine Displacement Specs

  • 1.8 L (1,797 cc)
  • 2.0 L (1,997 cc)
  • 2.3 L (2,299 cc)
  • 2.5 L (2,463 cc)
  • 2.5 L (2,498 cc)

M102 Engine Variants and Vehicle Applications

M102.910

Used in the W201 190E 1.8 from 1990 onwards (badged as 180E in Australia from 1991 to 1993). Cubic capacity: 1,797 cc (1.8 L) Power output: 80 kW (109 PS; 107 bhp) Torque: 154 Nm (114 lb ft)

Applications:

1990-1993 W201 180E and 190E 1.8


M102.920

The M102.920 was a 2.0 L engine with an bore and stroke 89 mm × 80.25 mm (3.50 in × 3.16 in). Equipped w/ carburettor 175 CDT. Cubic capacity: 1,997 cc (2.0 L) Power output: 80 kW (109 PS; 107 bhp).

Applications:

1980-1986 W123 200

1980-1986 W123 200T


M102.921

Similar to M102.920, but less power due to a different camshaft and different carburettor. Power Output: 66 kW (90 PS; 89 bhp)

Applications:

1983-1985 W201 190 (201.022)


M102.922

An update of the M102.920 engine for use in the W124 chassis Cubic capacity: 1,997 cc (2.0 L) Power output: 80 kW (109 PS; 107 bhp).

Applications:

1985-1992 W124 200


M102.924

Similar to M102.921, different carburetor, single-belt drive for alternator, power steering pump and air-conditioning compressor (where fitted). Hydraulic aided valve-train. Power output: 77 kW (105 PS; 103 bhp).

Application

1986-1990 W201 190 (201.023)


M102.938

Low compression version of M102.921 Power output: 63 kW (86 PS; 84 bhp).

Application

W201 190


M102.939

Low compression version of M102.920 Power output: 74 kW (101 PS; 99 bhp).

Application

W123 200

W123 200T


M102.961

A 2.0 L multi-point fuel-injected (KE-Jetronic) variation of the M102.921. An "E" was added to the model of the vehicle (standing for "einspritzung", the German word for fuel injection). This engine is identified by TSZ ignition and multiple belts for the alternator, power steering and air conditioning compressor (where fitted). Cubic capacity: 1,997 cc (2.0 L) Power output: 90 kW (122 PS; 121 bhp)

Application

1983-1985 W201 190E


M102.962

An update to the M102.961 introduced in 1985, with a power output of about 90 PS (89 bhp; 66 kW). This is identified by the EZL ignition system and a single accessory drive belt. Cubic capacity: 1,997 cc (2.0 L) Power output: 87 kW (118 PS; 117 bhp)

Applications:

1985-1993 W201 190E


M102.963

2.0–litre version with KE-Jetronic fuel injection. Cubic capacity: 1,997 cc (2.0 L) Power output: 90 kW (122 PS; 121 bhp)

Applications:

1985-1992 W124 200E, w201 190e 2.0 L.


M102.964

2.0–litre version with KE-Jetronic fuel injection for the Italian W460. Cubic capacity: 1,997 cc (2.0 L) Power output: 90 kW (122 PS; 121 bhp)

Applications:

1986-1989 W460 200GE 2.0 L.


M102.980

The M102.980 was a 2.3 L version with a 95.5 mm (3.76 in) bore and the same 80.25 mm (3.16 in) stroke. Power output was 100 kW (136 PS; 134 bhp). Engine weight was 118 kg (260 lb). Used K-jetronic fuel injection. Cubic capacity: 2,299 cc (2.3 L) Power output: 100 kW (136 PS; 134 bhp)

Applications:

1980-1986 W123 230E

1980-1986 W123 230CE

1980-1986 W123 230TE


M102.981

The M102.981 was a 2.3 L version with a 95.5 mm (3.76 in) bore and the same 80.25 mm (3.16 in) stroke. Cubic capacity: 2,299 cc (2.3 L) Power output: 92 kW (125 PS; 123 bhp)

Applications:

1979-1989 W460 230GE Geländewagen


M102.982

This motor resembled the M102.980 version, but modified slightly with a newer KE-Jetronic system from Bosch. Cubic capacity: 2,299 cc (2.3 L) Power output: 97 kW (132 PS; 130 bhp)

Applications:

1985-1992 W124 230E

1985-1992 W124 230CE

1985-1992 W124 230TE


M102.983

A 16-valve version of the M102.985 with cylinder head designed by Cosworth. Cubic capacity: 2,299 cc (2.3 L) Power output: 138 kW (188 PS; 185 bhp); USA: 125 kW (170 PS; 168 bhp)

Applications:

1986-1987 W201 190E 2.3-16


M102.985

An 8-valve M102 with a displacement of 2.3 L used in the W201 chassis with KE-Jetronic fuel injection. Cubic capacity: 2,299 cc (2.3 L) Power output: 97 kW (132 PS; 130 bhp)

Applications:

1985-1992 W201 190 E 2.3


M102.990

An update of the 16-valve version with increased capacity (2.5 L) and stiffening ribs, still with a cylinder head designed by Cosworth. Cubic capacity: 2,498 cc (2.5 L) Power output: 150 kW (204 PS; 201 bhp)

Applications:

1988-1993 W201 190E 2.5-16


M102.991

An update of the 2.5 16-valve version, with shorter stroke and larger bore. H beam rods and piston cooling jets. Cubic capacity: 2,498 cc (2.5 L) Power output: 147 kW (200 PS; 197 bhp)

Applications:

1989 W201 190E 2.5-16 Evolution I


M102.992

An update of the 102.991 version with removal of four crankshaft counterweights and even more stiffening ribs for higher RPMs. Single timing chain, oil pump with separate drive chain. Bigger Intake manifold, camshaft and exhaust system. Higher compression ratio 10,5:1. Cubic capacity: 2,463 cc (2.5 L) Power output: 173 kW (235 PS; 232 bhp)

Applications:

1990 W201 190E 2.5-16 Evolution II