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Mercedes-Benz Service Manual Engine 601
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Workshop manual for the Mercedes-Benz OM601 4-cylinder inline 2.2-liter diesel engine.
Includes factory technical information for engine diagnosis, inspection, disassembly, adjustment and repair, with content applicable to the Mercedes-Benz 190 D 2.2 from the W201 series (chassis 201.122) and also useful as a reference for other Mercedes-Benz models equipped with the OM601 engine.
PDF in English | 404 pages | Instant download.
- Factory technical data and specifications
- Inspection, disassembly and adjustment procedures
- Service content covering injection, timing, lubrication and cooling
- Useful for repair, maintenance and restoration
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Mercedes-Benz Service Manual Engine 601 | PDF
Workshop manual for the Mercedes-Benz OM601 4-cylinder inline 2.2-liter diesel engine.
The Mercedes-Benz OM601 is a four-cylinder inline diesel engine used in several Mercedes-Benz passenger car applications during the 1980s and early 1990s. In the version covered by this manual, it combines a single overhead camshaft layout, mechanical diesel injection and prechamber combustion, making this edition especially relevant for readers looking for a Mercedes-Benz OM601 service manual, OM601 workshop manual or 190 D 2.2 engine manual.
This digital PDF edition was originally created as a workshop service manual and includes diagnostic, inspection, disassembly, adjustment, repair and parts replacement procedures for the application expressly identified as 601.921, corresponding to the Mercedes-Benz 190 D 2.2. It is also useful as a general technical reference for other OM601 engine variants.
To review the scope of the contents and the included procedures in greater detail, please also check the Complete Index tab.
Main topics covered in the Mercedes-Benz OM601 engine manual
- General engine data and factory technical specifications
- Engine block, cylinder head, crankcase and engine breather system
- Crankshaft, connecting rods, pistons, cylinders and seals
- Timing system, camshaft, valves, chain and tensioner
- Diesel injection system, injection pump, injectors and timing adjustment
- Air cleaner, accessory belt, intake, exhaust and emission control
- Engine electrical system and related auxiliary components
- Lubrication system, oil pump, filtration and oil pan
- Cooling system, water pump, thermostat and fan
- Engine mounts, accelerator control, fuel system and exhaust system
Mercedes-Benz vehicles where the OM601 engine can be found
- W201 series: 190 D 2.2 and other diesel applications within the OM601 family depending on version.
- W124 series: 200 D and 200 TD in certain four-cylinder diesel variants.
- W202 series: C 200 Diesel / C 200 D in some early versions depending on market.
Important: the manual expressly identifies the 190 D-2.2, chassis 201.122 and engine 601.921 application. The other applications listed above are only intended as a general guide within the OM601 engine family.
Thanks to its technical approach and level of detail, this digital edition is valuable not only for workshops, but also for restorers, experienced mechanics and advanced enthusiasts who need to consult specific procedures without relying on a full printed copy.
Product details:
- Format: PDF
- Language: English
- Pages: 404
- Delivery method: Download link
Frequently asked questions about the Mercedes-Benz OM601 engine manual
Does this manual cover only one OM601 version or is it useful for several?
The application expressly identified in the manual corresponds to engine 601.921 from the 190 D 2.2 W201 chassis. However, the introduction itself explains that when engine 601 is mentioned, the content may also serve as a general reference for engines within the 601 family, so it can also be useful for other OM601 variants.
Does it include information about the diesel injection system?
Yes. The manual includes a dedicated group for the injection system and covers procedures involving the injection pump, injectors, nozzles, idle control, injection timing checks and adjustment, as well as fuel circuit inspections.
Does it include cylinder head, timing and chain-related content?
Yes. It includes procedures related to the engine block and cylinder head, crankshaft, pistons, camshaft, valves, timing chain, tensioner and guides, along with compression, leak and mechanical timing checks.
Can this manual help confirm whether my OM601 engine matches the covered application?
Yes. The manual expressly identifies engine 601.921, corresponding to the Mercedes-Benz 190 D 2.2. That makes it useful for checking whether your engine code matches the application covered by this edition before using it as your main technical reference.
Is this PDF only useful for major repairs?
Not necessarily. In addition to disassembly and repair operations, it also includes technical data, inspections, reference values, adjustments and procedures that are useful for maintenance, diagnosis and engine condition assessment.
What type of user can benefit most from this edition?
It was created as a workshop service manual, but it is also highly useful for restorers, independent mechanics, experienced owners and enthusiasts who want to understand more precisely how the OM601 engine is organized and what procedures the manual covers.
Mercedes-Benz Service Manual Engine OM601 | Index
This index reproduces the main sections and job numbers included in the Mercedes-Benz Service Manual Engine 601.
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
01 Crankcase and cylinder head
- 01-010 Checking compression pressure
- 01-015 Checking cylinders for leaks
- 01-020 Evaluating cylinder bores
- 01-030 Removal and installation of engine (oil capacity)
- 01-040 Crankcase breather - operation
- 01-110 Measuring cylinder bores
- 01-115 Renewing, boring and honing cylinder liners
- 01-120 Facing cylinder crankcase parting surface
- 01-130 Knocking out and inserting steel balls in main oil duct
- 01-140 Replacing core hole cover in cylinder crankcase
- 01-210 Removal and installation of timing housing cover
- 01-222 Removal and installation of end cover
- 01-310 Removal and installation of oil pan
- 01-405 Cylinder head screws and tightening cylinder head screws
- 01-415 Removal and installation of cylinder head
- 01-417 Removal and installation of prechambers
- 01-418 Facing cylinder head parting surface
- 01-420 Pressure-testing cylinder head
03 Crankshaft assembly
- 03-310 Checking, renewing and tightening connecting rod bolts
- 03-313 Reconditioning and squaring connecting rods
- 03-316 Removal and installation of pistons
- 03-318 Checking and reconditioning of crankshaft
- 03-320 Mounting of crankshaft
- 03-324 Replacing front crankshaft radial sealing ring
- 03-327 Replacing rear crankshaft radial sealing ring
- 03-330 Removal and installation of radial ball bearing in crankshaft
- 03-341 Removal and installation of crankshaft pulley and hub
- 03-345 Checking and correcting adjustment of TDC transmitter
- 03-350 Removal and installation of crankshaft timing gear
- 03-410 Removal and installation of flywheel and driven plate
- 03-420 Refinishing of flywheel
- 03-430 Renewing ring gear of flywheel
05 Engine timing, valves
- 05-211 Checking and replacement of hydraulic valve clearance compensating elements
- 05-215 Checking camshaft timing
- 05-220 Removal and installation of camshaft
- 05-250 Removal and installation of valve springs
- 05-260 Checking valve springs
- 05-270 Replacing valve stem seals
- 05-280 Checking and machining valves
- 05-290 Replacing valve seat rings
- 05-291 Machining valve seats
- 05-310 Removal and installation of chain tensioner
- 05-320 Replacing timing chain
- 05-330 Removal and installation of tensioning rail
- 05-341 Removal and installation of slide rails
- 05-437 Removal and installation of drive for hydraulic oil pump
07.1 Injection system
- 07.1-001 Survey engine-injection pump-injection nozzle-nozzle holder
- 07.1-010 Operation of injection system
- 07.1-011 Operation of injection nozzles
- 07.1-012 Operation of fuel preheater
- 07.1-100 Adjustment of idle speed
- 07.1-102 Checking pneumatic idle speed increase
- 07.1-104 Checking engine output and exhaust gas on chassis dynamometer
- 07.1-109 Checking injection timing (high-pressure method)
- 07.1-111 Checking injection timing (position pickup-RIV method)
- 07.1-112 Checking injection timing with digital tester (RIV method)
- 07.1-115 Adjusting injection timing (high-pressure method) - following checkup
- 07.1-116 Adjusting injection timing (position pickup-RIV method) - following checkup
- 07.1-117 Adjusting injection timing with digital tester (RIV method) - following checkup
- 07.1-135 Checking injection nozzles
- 07.1-137 Disassembling, cleaning, assembling and adjusting injection nozzles (following checkup)
- 07.1-145 Checking fuel pump
- 07.1-150 Checking vacuum shutoff for leaks
- 07.1-200 Removal and installation of injection pump
- 07.1-210 Renewing delivery valve seal
- 07.1-220 Renewing vacuum control unit
- 07.1-230 Removal and installation of injection nozzle
- 07.1-235 Removal and installation of fuel pump
- 07.1-240 Removal and installation of injection timer
- 07.1-245 Renewing fuel filter
09 Air cleaner
- 09-400 Removal and installation of air cleaner
13 Belt drive
- 13-340 Removal and installation of V-belt
14 Intake manifold, exhaust manifold, emission control system
- 14-050 Operation of emission control system
- 14-100 Checking emission control system
- 14-180 Removal and installation of intake manifold
- 14-350 Removal and installation of exhaust manifold
15 Electrical system, engine
- 15-505 Operation of preglow system
- 15-510 Checking preglow system
- 15-515 Removal and installation of glow plugs
- 15-600 Testing alternator with regulator in vehicle
- 15-642 Renewing fan assembly
- 15-700 Removal and installation of starter
18 Engine lubrication
- 18-005 Oil circuit, oil pressure, pressure relief and bypass valve, oil filter
- 18-110 Removal and installation of oil filter
- 18-210 Removal and installation of oil pump
- 18-215 Removal and installation of oil pressure relief valve
20 Engine cooling
- 20-005 Coolant circuit and engine cooling
- 20-010 Draining and filling in coolant - antifreeze table
- 20-015 Cleaning cooling system
- 20-110 Removal and installation of thermostat
- 20-210 Removal and installation of coolant pump
- 20-230 Removal and installation of coolant pump housing
- 20-330 Magnetic fan coupling
- 20-335 Removal and installation of magnetic fan coupling
- 20-420 Removal and installation of radiator
- 20-425 Repairing radiator
- 20-430 Checking expansion tank closing cap
22 Engine suspension
- 22-211 Removal and installation of front engine mounts
- 22-212 Removal and installation of rear engine mount
- 22-215 Removal and installation of front engine stop
- 22-220 Adjusting engine stop
- 22-240 Removal and installation of engine shock absorber
30 Throttle control
- 30-300 Adjusting control linkage
- 30-315 Removal and installation of front wall bearing for accelerator lever
- 30-325 Removal, installation and adjustment of bowden cable
- 30-330 Removal and installation of accelerator pedal
- 30-335 Lubrication of control linkage and control shafts
47 Fuel system
- 47-020 Operation of immersion tube transmitter for fuel readout
- 47-030 Operation of fuel tank positive and negative venting
- 47-100 Removal and installation of fuel tank
- 47-120 Removal and installation of immersion tube transmitter
49 Exhaust system
- 49-100 Removal and installation of exhaust system
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Workshop manual for the Mercedes-Benz OM601 4-cylinder inline 2.2-liter diesel engine.
Includes factory technical information for engine diagnosis, inspection, disassembly, adjustment and repair, with content applicable to the Mercedes-Benz 190 D 2.2 from the W201 series (chassis 201.122) and also useful as a reference for other Mercedes-Benz models equipped with the OM601 engine.
PDF in English | 404 pages | Instant download.
- Factory technical data and specifications
- Inspection, disassembly and adjustment procedures
- Service content covering injection, timing, lubrication and cooling
- Useful for repair, maintenance and restoration