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Mercedes Benz Service Manual Engines 615, 616, 617.91
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Workshop manual for OM615 2.2-liter 4-cylinder, OM616 2.4-liter 4-cylinder, and OM617.91 3.0-liter 5-cylinder engines
Includes factory technical information for diagnosis, inspection, disassembly, measurement, adjustment, assembly and repair, with content covering OM615, OM616 and OM617.91 engines fitted to 220 D, 240 D, 300 D, 300 CD and 300 TD models, and also useful as a workshop reference for other classic Mercedes-Benz diesel vehicles using these robust engines.
English PDF | 742 pages | Instant download.
- Factory technical data, service tables and original specifications
- Inspection, disassembly, measurement, adjustment and assembly procedures
- Coverage of block, cylinder head, crankshaft, timing and diesel injection
- Useful information for repair, maintenance, restoration and workshop jobs
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Mercedes-Benz Service Manual Engines 615, 616, 617.91 | PDF
Workshop manual for the OM615 2.2-liter 4-cylinder engine, the OM616 2.4-liter 4-cylinder engine, and the OM617.91 3.0-liter 5-cylinder engine.
The OM615, OM616 and OM617.91 engines belong to one of Mercedes-Benz’s best-known classic diesel families, used in W115 and W123 sedans, coupes and station wagons, while also serving as a valuable reference for off-road vehicles and commercial vehicles fitted with closely related engines from the same family. Known for their durability, mechanical simplicity and long-standing popularity among enthusiasts, these engines remain highly relevant for maintenance, diagnostics, full repair work and restoration projects.
This digital PDF edition provides factory service information for testing, disassembly, measurement, adjustment, assembly, installation and repair, with direct coverage for engine units 615.912, 616.916, 616.912, 617.910 and 617.912. Its content preserves the original Mercedes-Benz workshop structure and includes practical procedures for both partial service work and more extensive engine repairs.
If you want to review the scope of the content in more detail before purchasing, you can also check the Complete Index tab, where the groups and workshop operations included in the manual are listed.
Main topics covered in the Mercedes-Benz OM615, OM616 and OM617.91 manual
- General engine data and technical specifications
- General jobs covering several component groups
- Engine block, crankcase and crankshaft assembly
- Cylinder head, timing, oil pump and injection pump drive
- Diesel injection system
- Air filter
- Belt drive
- Intake and exhaust manifolds, including emission control system
- Engine electrical system and preglow system
- Lubrication system and engine oil cooling
- Cooling system
- Accelerator control
- Fuel system
- Exhaust system
Mercedes-Benz vehicles with OM615, OM616 and OM617.91 engines covered in the manual
- W115 series: 220 D, 240 D, 240 D 3.0 and 300 D
- W123 series: 240 D, 300 D, 300 CD and 300 TD
Other Mercedes-Benz vehicles where this manual may be useful as a reference
- W115 series: 200 D
- W123 series: 200 D
- W460 series: 240 GD and 300 GD
- W631 series: MB 100 D
- T1/TN series: 207 D, 307 D and 407 D | 209 D, 309 D and 409 D
Note: the vehicles in the second group are not among the main applications specifically developed in this edition. However, because they use engines from the same family or very close OM615, OM616 and OM617 variants, many of the mechanical procedures, inspection values and workshop operations can still be useful as a reference.
Product details:
- Format: PDF
- Language: English
- Pages: 742
- File size: 77.7 MB
- Delivery method: Download link
This digital PDF edition preserves the original Mercedes-Benz technical nomenclature and is practical to consult from a desktop computer, tablet or smartphone during diagnosis, teardown, measurement, adjustment, assembly and restoration work on classic diesel engines.
Frequently asked questions about the Mercedes-Benz OM615, OM616 and OM617.91 manual
Does this manual cover more than one classic Mercedes-Benz diesel engine?
Yes. This edition covers the OM615, OM616 and OM617.91 engines, including different internal variants documented by Mercedes-Benz in this technical publication.
Does it include information on diesel injection and the preglow system?
Yes. The technical groups in the manual include the diesel injection system and the engine electrical system with preglow, two key sections for diagnosing and repairing these engines.
Is it useful for complete repair work as well as routine maintenance?
Yes. The content goes beyond basic service tasks, since it includes disassembly, measurement, adjustment, assembly and installation procedures suitable for more extensive repair work.
Can it be useful for restoring W115 and W123 diesel vehicles?
Yes. Based on the covered models and engines, it is a very useful reference for restoration, preservation and tune-up work on classic Mercedes-Benz diesel vehicles.
Does the manual include tables, technical data and supporting illustrations?
Yes. The publication includes specifications, service data, technical organization schemes and supporting illustrations that help identify components and follow the procedures more accurately.
Mercedes-Benz OM615, OM616 and OM617.91 engine manual | Index
This index lists the main sections and job numbers included in the Mercedes-Benz Service Manual Engines 615, 616, 617.91.
Entries are presented according to the original technical structure and numbering of the manual.
0 General, Technical Data
- A Instructions for Use of Service Manual
- 00-005 Model and Unit Survey
- 00-010 Technical data
00 Engine jobs which comprise several design groups
- 00-110 Removal and installation of engine (oil quantity)
- 00-115 Checking compression pressure
- 00-120 Checking cylinders for leakage
- 00-130 Measurement of oil consumption
- 00-211 Removal and installation of front engine mounts
- 00-212 Removal and installation of rear engine mount
- 00-215 Removal and installation of front engine stop
- 00-220 Adjustment of engine stop
- 00-240 Removal and installation of engine shock absorber
- 00-241 Retrofitting engine shock absorber (engines 615, 616 in type 123.1)
- 00-242 Retrofitting engine shock absorber (engine model 617 in type 123.1)
- 00-310 Engine ventilation - Functional description
03 Cylinder crankcase and crank assembly
- 03-008 Assessment of cylinder bores
- 03-010 Measurement of cylinder bores
- 03-015 Refacing crankcase parting surface
- 03-020 Renewing, boring and honing cylinder liners
- 03-030 Removal and insertion of steel balls for main oil galleries
- 03-040 Replacement of core hole caps in crankcase
- 03-110 Installation and centering of intermediate flange
- 03-210 Removal and installation of oil pan assembly
- 03-310 Checking, replacement and tightening of big-end clamp bolts
- 03-313 Reconditioning and squaring connecting rods
- 03-316 Removal and installation of piston
- 03-318 Checking and reconditioning crankshaft
- 03-320 Refitting crankshaft bearings
- 03-324 Replacement of front radial seal on crankshaft
- 03-327 Replacement of aft radial seal on crankshaft
- 03-330 Removal and installation of deep-groove ball bearing and locking ring in crankshaft
- 03-340 Removal and installation of pulley, vibration damper and balance plate
- 03-344 Balancing balance plate statically
- 03-345 Checking and correcting adjustment of TDC transmitter adjusting slide
- 03-350 Removal and installation of crankshaft sprocket
- 03-410 Removal and installation of flywheel and driven plate
- 03-420 Refacing flywheel
- 03-430 Replacement of flywheel ring gear
- 03-440 Balancing flywheel statically
- 03-450 Notes on overall balancing of engine 617
05 Cylinder head and engine timing, oil pump and injection pump drive
- 05-100 Repair instructions for cylinder heads and cylinder head gaskets
- 05-105 Cylinder head bolts and cylinder head bolt torquing
- 05-110 Retightening hexagon socket cylinder head bolts
- 05-115 Removal and installation of cylinder head
- 05-117 Removal and installation of precombustion chambers
- 05-118 Refacing cylinder head parting surface
- 05-120 Pressure-testing cylinder head
- 05-135 Checking and replacing valve guides
- 05-155 Refacing valve seats
- 05-210 Checking and adjusting valve clearance
- 05-215 Checking and adjusting camshaft timing
- 05-220 Removal and installation of camshaft
- 05-225 Grinding camshaft journals
- 05-235 Removal and installation of rocker arms and rocker arm brackets
- 05-240 Replacement of rocker arms and rocker arm brackets
- 05-250 Removal and installation of valve springs
- 05-260 Checking valve springs
- 05-270 Replacing valve stem seals
- 05-280 Checking and refacing valves
- 05-310 Removal and installation of chain tensioner
- 05-320 Replacement of timing chain
- 05-330 Removal and installation of tension rail
- 05-340 Removal and installation of slide rails
- 05-410 Removal and installation of helical gear shaft
- 05-412 Removal and installation of intermediate gear shaft
- 05-440 Removal and installation of idler gear
07.1 Diesel injection system
- 07-001 Survey engine - model - injection pump
- 07-010 Operation of injection pump and rpm governor
- 07-100 Adjustment of idle speed and idle speed adjuster
- 07-105 Inspection and adjustment of no-load max speed
- 07-109 Checking injection pump for beginning of delivery (according to high pressure overflow method)
- 07-110 Checking injection pump for beginning of delivery (according to low pressure overflow method)
- 07-115 Adjusting injection pump for beginning of delivery (after checking beginning of delivery)
- 07-120 Checking injection pump for offset of beginning of delivery (after checking beginning of delivery of cylinder 1)
- 07-125 Checking pneumatic governor of injection pump for leaks (engine 615, 616)
- 07-130 Adjusting governor spring of injection pump (engine 615, 616)
- 07-135 Checking injection nozzles
- 07-137 Disassembly, cleaning, assembly and adjustment of injection nozzles
- 07-140 Venting of injection system
- 07-145 Checking fuel pump and overflow valve
- 07-150 Checking key starter for leaks
- 07-200 Removal and installation of injection pump
- 07-205 Displacing injection pump (after adjusting beginning of delivery)
- 07-210 Replacing pipe connection, pressure valve or copper sealing ring of injection pump
- 07-215 Replacing diaphragm of injection pump, adjusting compensating path (engine 615, 616 M-injection pump with pneumatic governor)
- 07-220 Replacing vacuum box on injection pump
- 07-225 Replacing altitude adjusting box
- 07-230 Removal and installation of injection nozzles (injectors)
- 07-235 Removal and installation of fuel pump
- 07-240 Removal and installation of injection timer
- 07-245 Replacing fuel filter
09 Air filter
- 09-400 Removal and installation of air filter
13 Belt drive
- 13-335 Instructions on renewing and tensioning V-belts
- 13-340 Tensioning V-belts
14 Intake manifold, exhaust manifold, emission control system
- 14-001 Identification of vehicles in national version
- 14-050 Functional description, exhaust gas recycling (USA)
- 14-100 Trouble-shooting
- 14-450 Removal and installation of intake pipe, replacement of gasket
- 14-470 Removal and installation of exhaust manifold
15 Electrical system engine (preglow system)
- 15-505 Operation of preglow system
- 15-510 Checking preglow system
- 15-512 Damage on filament-type glow plugs and its cause
- 15-515 Removal and installation of glow plugs
- 15-520 Adjustment of cable control
- 15-535 Removal and installation of preglow starter switch with cable control
18 Engine lubrication, engine oil cooling
- 18-005 Oil circuit, oil pressure, pressure relief valve and oil filter
- 18-110 Removal and installation of oil filter
- 18-120 Checking thermostat in oil filter
- 18-125 Removal and installation of thermostat in 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 of coolant - Anti-freeze table
- 20-015 Cleaning the cooling system
- 20-110 Removal and installation of thermostat
- 20-210 Removal and installation of water pump
- 20-220 Reconditioning of water pump
- 20-225 Sealing of water pump
- 20-230 Removal and installation of water pump
- 20-310 Viscofan coupling, temperature-controlled (engine 617)
- 20-420 Removal and installation of radiator
- 20-425 Reconditioning of radiator
- 20-430 Checking radiator cap
- 20-490 Thermostat layout
30 Accelerator control
- 30-300 Adjusting regulating linkage, vehicles with left-hand steering
- 30-310 Removal and installation of engine longitudinal regulating shaft
- 30-320 Removal, installation and adjustment of front wall regulating shaft
- 30-330 Removal and installation of accelerator pedal
- 30-340 Adjusting start and stop cable control (engine 615, 616 with M-injection pump)
47 Fuel system
- 47-700 Removal and installation of fuel tank
- 47-705 B. Model 123.1 T-sedans
- 47-710 Removal and installation of immersion tube transmitter
- 47-715 Functional description of immersion tube transmitter for fuel gauge
- 47-720 Functional description of fuel tank positive and negative venting system
49 Exhaust system
- 49-100 Removal and installation of exhaust system
Extract from introductory brochure
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Workshop manual for OM615 2.2-liter 4-cylinder, OM616 2.4-liter 4-cylinder, and OM617.91 3.0-liter 5-cylinder engines
Includes factory technical information for diagnosis, inspection, disassembly, measurement, adjustment, assembly and repair, with content covering OM615, OM616 and OM617.91 engines fitted to 220 D, 240 D, 300 D, 300 CD and 300 TD models, and also useful as a workshop reference for other classic Mercedes-Benz diesel vehicles using these robust engines.
English PDF | 742 pages | Instant download.
- Factory technical data, service tables and original specifications
- Inspection, disassembly, measurement, adjustment and assembly procedures
- Coverage of block, cylinder head, crankshaft, timing and diesel injection
- Useful information for repair, maintenance, restoration and workshop jobs