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Mercedes-Benz Service Manual Diesel Engines 602, 603
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Workshop manual for Mercedes-Benz OM602 and OM603 diesel engines, covering 2.5-, 3.0- and 3.5-liter versions.
Includes factory technical information for diagnosis, inspection, disassembly, measurement, adjustment, and repair, with content applicable to OM602 and OM603 engines in the W201, W124, and W126 series, and also useful as a technical reference for other Mercedes-Benz models equipped with these engines.
PDF in English | 1018 pages | Instant download.
- Technical data, factory specifications, and service tables
- Inspection, disassembly, measurement, adjustment, and assembly procedures
- Content covering the cylinder head, crankshaft, valvetrain, diesel injection, turbocharger, and preglow system
- Useful information for repair, maintenance, and restoration of OM602 and OM603 engines
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Mercedes-Benz Service Manual Diesel Engines 602, 603 | PDF
Workshop manual for Mercedes-Benz OM602 and OM603 diesel engines, covering 2.5-, 3.0-, and 3.5-liter versions.
The Mercedes-Benz OM602 and OM603 belong to one of the brand’s best-known diesel engine families, recognized for mechanical robustness, solid performance under intensive use, and widespread use across numerous late-1980s and early-1990s models. In the versions covered by this manual, they combine a single overhead camshaft layout, mechanical prechamber injection, and, depending on application, either naturally aspirated or turbocharged configuration, which is why they remain highly consulted for maintenance, repair, and restoration work.
This digital PDF edition was originally created as a workshop service manual and includes diagnostic, inspection, disassembly, measurement, adjustment, assembly, repair, and parts replacement procedures for engines 602.911, 602.961, 602.962, 603.960, 603.961, and 603.970. The content is oriented to Mercedes-Benz applications in the W201, W124, and W126 series, while also being useful as a general technical reference for other Mercedes-Benz models equipped with OM602 and OM603 engines.
To review the scope of the content and included operations in greater detail, please also check the Complete Index tab.
Main topics covered in the Mercedes-Benz OM602 and OM603 manual
- General data and engine technical specifications
- Engine block, cylinder head, and main assembly components
- Crankshaft, moving assembly components, and lower-end assembly
- Timing, camshaft, valves, and synchronization
- Diesel injection system and related inspection procedures
- Air intake, air filter, turbocharger, and belt drive
- Intake and exhaust manifolds, including emission control content
- Engine electrical system and preglow circuit
- Lubrication, cooling, engine mounts, and accelerator control
- Fuel tank and lines, together with the exhaust system
Mercedes-Benz vehicles equipped with OM602 engine
- W124 Series: 250 D, 250 TD, 250 D Turbo, and 300 D 2.5 Turbo
- W201 Series: 190 D 2.5 and 190 D 2.5 Turbo
- W460 Series: 250 GD
- W463 Series: 250 GD
Mercedes-Benz vehicles equipped with OM603 engine
- W124 Series: 300 D Turbo and 300 TD Turbo
- W126 Series: 300 SD Turbo, 300 SDL Turbo, 350 SD Turbo, and 350 SDL Turbo
- W140 Series: S 350
- W463 Series: 300 GD
Important: This is a reference list of vehicles that used versions of the OM602 and OM603 engines. Other applications within the OM602 and OM603 family may require verification according to market, version, and configuration.
Item details:
- Format: PDF
- Language: English
- Pages: 1018
- File size: 65.4 MB
- Delivery method: Download link
Thanks to its technical approach and level of detail, this digital edition is especially useful for workshops, restorers, experienced mechanics, and owners who need to consult specific procedures without depending on a complete printed copy.
Frequently asked questions about the Mercedes-Benz OM602 and OM603 engine manual
Which engine codes are included in this edition?
This edition brings together service information for engines 602.911, 602.961, 602.962, 603.960, 603.961, and 603.970, belonging to the Mercedes-Benz OM602 and OM603 engine families.
Does it include information on diesel injection, turbocharging, and preglow?
Yes. The manual covers the diesel injection system, air intake, air filter, turbocharger, and the engine electrical system with preglow circuit.
Does it cover the cylinder head, crankshaft, and timing system?
Yes. It includes service procedures and data related to the engine block, cylinder head, crankshaft assembly, timing components, camshaft, valves, and mechanical synchronization.
Is it only useful for W201, W124, and W126 vehicles?
The content is explicitly oriented to applications in those series, but it can also be useful as a technical reference for other Mercedes-Benz models equipped with OM602 or OM603 engines, provided the exact configuration is verified.
Does this manual include service specifications, test values, and adjustment data?
Yes. In addition to repair and disassembly procedures, the manual includes factory technical data, service specifications, inspection values, and adjustment information useful for diagnosis, maintenance, and engine assembly work.
Is this PDF only useful for major repairs?
No. In addition to disassembly and repair procedures, it also includes technical data, inspections, test values, adjustments, and useful procedures for maintenance, diagnosis, and general mechanical follow-up.
Mercedes-Benz OM602 and OM603 Diesel Engine Manual | Index
This index lists the main sections and job numbers included in the Mercedes-Benz Service Manual Diesel Engines 602, 603.
Entries are presented according to the original technical structure and numbering of the manual.
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
- 01-001 Engine and model survey
- 01-006 Removal and installation of noise capsule at bottom of engine compartment
- 01-008 Opening hood, setting vertical, warnings
- 01-010 Testing 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 ventilation - Function
- 01-110 Measuring, boring and honing cylinder bores
- 01-115 Boring, honing and replacement of cylinder sleeves
- 01-120 Planing crankcase parting surface
- 01-130 Removal and installation of steel balls in main oil duct
- 01-140 Replacement of freeze plugs in crankcase
- 01-210 Removal and installation of timing cover
- 01-222 Removal and installation of end cover
- 01-310 Removal and installation of oil pan
- 01-400 Repair notes for cylinder heads and cylinder head gaskets
- 01-410 Refinishing prechamber sealing surface
- 01-415 Removal and installation of cylinder head
- 01-417 Removal and installation of prechambers
- 01-418 Facing cylinder head mating surface
- 01-419 Boring out camshaft bearing bores (repair stage)
- 01-420 Pressure-testing cylinder head
03 Crankshaft Assembly
- 03-310 Checking, replacing and tightening connecting rod bolts
- 03-313 Reconditioning and squaring connecting rods
- 03-316 Removal and installation of pistons
- 03-317 Modifications to pistons
- 03-318 Checking and reconditioning crankshaft
- 03-320 Installation of crankshaft and connecting rod bearings
- 03-321 Modifications to crankshaft
- 03-324 Replacing front crankshaft radial sealing ring
- 03-327 Replacing rear crankshaft radial sealing ring
- 03-330 Removal and installation of pilot bearing in crankshaft
- 03-341 Removal and installation of crankshaft pulley and hub
- 03-345 Checking and correcting adjustment of TDC sensor
- 03-350 Removal and installation of crankshaft sprocket
- 03-410 Removal and installation of flywheel and driven plate
- 03-420 Refinishing flywheel
- 03-430 Replacing ring gear
05 Engine Timing, Valvetrain
- 05-211 Checking and renewal 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 of valve stem seals
- 05-280 Checking and machining valves
- 05-285 Checking and replacing valve guides
- 05-290 Replacing valve seat inserts
- 05-291 Machining valve seats
- 05-310 Removing and installing chain tensioner
- 05-320 Renewal of timing chain
- 05-330 Removal and installation of tensioner rail
- 05-341 Removal and installation of guide rail
- 05-437 Removal and installation of pressure oil pump drive
07.1 Diesel Injection System
- 07-001 Survey - injection pumps
- 07-002 Survey - injectors
- 07-003 Explanation of injection pump type plate
- 07-015 Function exhaust gas recirculation
- 07-100 Testing, adjusting idle speed
- 07-103 Checking electronic idle speed control
- 07-105 Checking electronic idle speed control (ELR)
- 07-110 Checking, tuning engine
- 07-111 Checking start of delivery (position sensor RIV method)
- 07-112 Checking start of delivery with digital tester (RIV method)
- 07-113 Establishing fuel consumption by road test
- 07-116 Adjusting start of delivery (position sensor RIV method)
- 07-117 Adjusting start of delivery with digital tester (RIV method)
- 07-145 Checking fuel pump
- 07-146 Checking fuel pressure (after checking delivery capacity)
- 07-150 Testing vacuum shut-off for leaks
- 07-160 Testing vacuum pump
- 07-170 Testing and adjusting vacuum control valve for automatic transmission
- 07-195 Testing exhaust gas recirculation
- 07-200 Removal, installation of injection pump
- 07-210 Replacing delivery valve seal
- 07-220 Replacing vacuum unit
- 07-225 Replacing electromagnetic actuator (ELR)
- 07-230 Removal and installation of injectors
- 07-231 Checking injectors
- 07-232 Reconditioning injectors
- 07-235 Removal and installation of fuel pump
- 07-240 Removal and installation of injection timing device
- 07-241 Reconditioning injection timing device
- 07-245 Replacing fuel filter
- 07-400 Electrical wiring diagrams
- 07-500 Vacuum diagrams
07.1 Turbodiesel Injection System
- 07.1-001 Survey - injection pumps - Turbodiesel
- 07.1-002 Survey - injectors - Turbodiesel
- 07.1-003 Explanation of injection pump type plate - Turbodiesel
- 07.1-010 Function - injection system - Turbodiesel
- 07.1-100 Testing, adjusting idle speed - Turbodiesel
- 07.1-105 Testing electronic idle speed control with test connector (X92 and X11/4) - Turbodiesel
- 07.1-110 Testing, tuning engine - Turbodiesel
- 07.1-111 Testing start of delivery (position sensor RIV method) - Turbodiesel
- 07.1-112 Testing start of delivery - digital tester (RIV method) - Turbodiesel
- 07.1-113 Establishing fuel consumption by road test - Turbodiesel
- 07.1-116 Setting start of delivery (position sensor RIV method) following test - Turbodiesel
- 07.1-117 Setting start of delivery with digital tester (RIV) method) following testing - Turbodiesel
- 07.1-145 Testing fuel pump - Turbodiesel
- 07.1-146 Testing fuel pressure (after testing fuel delivery) - Turbodiesel
- 07.1-150 Testing vacuum engine stop for leaks - Turbodiesel
- 07.1-160 Testing vacuum pump - Turbodiesel
- 07.1-170 Testing and setting vacuum control valve for automatic transmission - Turbodiesel
- 07.1-180 Testing control rods travel sensor - Turbodiesel (Model Year 1986/87 only)
- 07.1-190 Testing electronic diesel system (EDS) - Turbodiesel
- 07.1-200 Removal and installation of injection pump - Turbodiesel
- 07.1-210 Replacing delivery valve seal - Turbodiesel
- 07.1-220 Replacing vacuum unit - Turbodiesel
- 07.1-225 Replacing actuator of electronic idle speed control (ELR) - Turbodiesel
- 07.1-230 Removal and installation of injectors - Turbodiesel
- 07.1-231 Testing injectors - Turbodiesel
- 07.1-232 Reconditioning injectors (after testing) - Turbodiesel
- 07.1-235 Removal and installation of fuel pump - Turbodiesel
- 07.1-240 Removal and installation of injection timing device - Turbodiesel
- 07.1-241 Reconditioning injection timing device - Turbodiesel
- 07.1-245 Replacing fuel filter - Turbodiesel
- 07.1-250 Retrofitting damper with restriction orifice - Turbodiesel
- 07.1-400 Wiring diagrams - Turbodiesel
- 07.1-500 Vacuum Circuit Diagrams - Turbodiesel
09 Air Intake System - Air Filter, Turbocharger
- 09-050 Function of turbocharger
- 09-100 Testing turbocharger boost pressure
- 09-150 Removal and Installation of turbocharger
- 09-200 Function of engine overload protection - Turbodiesel
- 09-250 Testing engine overload protection - Turbodiesel
- 09-400 Removal and installation of air cleaner
- 09-400 Removal and installation of air cleaner - Turbodiesel
13 Belt Drive
- 13-342 Removal and installation of poly V-belt
- 13-343 Checking condition of poly V-belt and tensioner
- 13-345 Removal, installation and dismantling of poly V-belt tensioner
14 Intake and Exhaust Manifold, Emission Control System
- 14-050 Function of trap oxidizer - Turbodiesel
- 14-100 Removal and installation of trap oxidizer - Turbodiesel
- 14-150 Testing exhaust backpressure - Turbodiesel
- 14-180 Removal and installation of intake manifold
- 14-180 Removal and installation of charge air pipe - Turbodiesel
- 14-200 Removal and installation of vacuum unit pressure control flap 1990 - Turbodiesel
- 14-350 Removal and installation of exhaust manifold
- 14-350 Removal and installation of exhaust manifold - Turbodiesel
15 Electrical System, Preglow
- 15-705 Function of preglow system
- 15-705 Function of preglow system - Turbodiesel
- 15-710 Checking preglow system without afterglow function
- 15-710 Checking preglow system without afterglow function - Turbodiesel
- 15-711 Checking preglow system with afterglow function
- 15-711 Testing preglow system with afterglow function - Turbodiesel
- 15-715 Removal and installation of glow plugs
- 15-715 Removal and installation of glow plugs - Turbodiesel
18 Engine Lubrication System
- 18-002 Engine oil and filter change
- 18-005 Oil circuit, oil pressure, overpressure and bypass valve, oil filter
- 18-040 Removal and installation of oil spray nozzles
- 18-045 Function of oil spray nozzles
- 18-110 Removal and installation of oil filter
- 18-115 Modifications to oil filter
- 18-210 Removal and installation of oil pump
- 18-212 Replacement of oil pump chain
- 18-215 Removal and installation of oil pressure relief valve
- 18-220 Testing oil level indicator
- 18-225 Function of oil level indicator
- 18-226 Removal and installation of oil level sensor
20 Engine Cooling System
- 20-005 Coolant circuit and engine cooling
- 20-010 Engine coolant replacement - Antifreeze table
- 20-015 Cleaning and flushing cooling and heating system
- 20-016 Removing oil from cooling and heating system
- 20-017 Checking cooling system for leaks
- 20-110 Removal and installation of thermostat
- 20-210 Removal and installation of coolant pump
- 20-215 Notes on coolant pump
- 20-230 removal and instllation of coolant pump housing
- 20-310 Temperature-controlled viscous fan coupling
- 20-312 Removal and installation of viscous fan cooupling
- 20-330 Magnestic fan coupling
- 20-335 Removal and installation of magnetic fan coupling
- 20-420 Removal and installation of radiator
- 20-425 Repairing radiator
- 20-430 Testing radiator or expansion tank cap
- 20-440 Testing coolant level indicator
- 20-445 Function of coolant level indicator
- 20-450 Removal and installation of overflow tank
22 Engine Suspension
- 22-210 Function of hydraulic engine mounts
- 22-212 Removal and installation of rear engine mount
- 22-215 Removal and installation off front engine stop
- 22-220 Adjusting engine stop
- 22-240 Removal and installation of engine shock absorber
30 Acelerator Control
- 30-300 Adjustment of accelerator control linkage
- 30-300 Adjusting Accelerator Control Linkage - Turbodiesel
- 30-315 Removal and installation of firewall bearing for accelerator lever
- 30-315 Removal and installation of firewallbearing for accelerator pedal lever - Turbodiesel
- 30-325 Removal, installation and adjustment of Bowden cable
- 30-325 Removal, adjusting and installation of Bowden cable
- 30-327 Adjusting longitudinal accelerator control shaft Model 126
- 30-330 Removal and installation of accelerator pedal
- 30-330 Removal and installation of accelerator pedal - Turbodiesel
- 30-335 Lubrication of accelerator control linkage and control shaft
- 30-335 Lubrication of accelerator control linkage and control shaft - Turbodiesel
- 30-400 Retrofitting accelerator control shaft and bearing bracket - Turbodiesel
47 Fuel Tank and Lines
- 47-010 Function of fuel tank with splash pot
- 47-020 Function of fuel gauge sending unit
- 47-020 Function of fuel gauge sending unit - Turbodiesel
- 47-030 Function of fuel tank breather and vent
- 47-030 Function of fuel tank ventilation - Turbodiesel
- 47-100 Removal and installation of fuel tank
- 47-120 Removal and installation of fuel gauge sending unit
49 Exhaust System
- 49-100 Removal and installation of exhaust system
- 49-100 Removal and installation of exhaust system - Turbodiesel
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Workshop manual for Mercedes-Benz OM602 and OM603 diesel engines, covering 2.5-, 3.0- and 3.5-liter versions.
Includes factory technical information for diagnosis, inspection, disassembly, measurement, adjustment, and repair, with content applicable to OM602 and OM603 engines in the W201, W124, and W126 series, and also useful as a technical reference for other Mercedes-Benz models equipped with these engines.
PDF in English | 1018 pages | Instant download.
- Technical data, factory specifications, and service tables
- Inspection, disassembly, measurement, adjustment, and assembly procedures
- Content covering the cylinder head, crankshaft, valvetrain, diesel injection, turbocharger, and preglow system
- Useful information for repair, maintenance, and restoration of OM602 and OM603 engines