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Mercedes-Benz Service Manual Engine 617.95 Turbo Diesel
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Workshop manual for the Mercedes-Benz OM617.95 Turbo Diesel 5-cylinder inline 3.0-liter diesel engine
Includes factory technical information for diagnosis, inspection, disassembly, measurement, adjustment and repair, covering 617.950, 617.951, 617.952 and 617.962 engines from the W116, W123 and W126 series, and useful as a workshop reference for maintenance, restoration and service work on OM617 turbo diesel applications.
PDF in English | 567 pages | Instant Download.
- Technical data, service specifications and filling capacities
- Inspection, disassembly, measurement, adjustment, assembly and repair procedures
- Coverage of cylinder head, crankshaft, valve timing, diesel injection and turbocharger systems
- Useful reference for repair, maintenance and restoration of the OM617 turbo diesel engine
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Mercedes-Benz Service Manual Engine 617.95 Turbo Diesel | PDF
Workshop manual for the Mercedes-Benz OM617.95 Turbo Diesel 5-cylinder inline 3.0-liter diesel engine, used in 300 SD, 300 TD, 300 D, and 300 CD models.
The Mercedes-Benz OM617.95 Turbo Diesel represents the turbocharged stage of the OM617 engine family used in Mercedes-Benz passenger cars between model years 1978 and 1985. In the versions covered by this edition, it combines a 4-stroke prechamber diesel design, 5 cylinders in line, 2998 cc, a single overhead camshaft, and a turbocharger, which is why it remains a highly consulted engine when proper maintenance, adjustment, or rebuilding work is required on a classic Mercedes-Benz.
This digital PDF edition includes factory technical information for diagnosis, inspection, disassembly, dimensional checking, adjustment, assembly, repair, and parts replacement for engines 617.950, 617.951, 617.952, and 617.962. The content is oriented to applications in the W116, W123, and W126 series, and can also be useful as a reference source for other Mercedes-Benz configurations based on the OM617 turbo, provided the exact engine version is verified.
To review the scope of the content and included procedures in greater detail, please also check the Complete Index tab.
Main topics covered in the Mercedes-Benz OM617.95 Turbo Diesel manual
- General data, engine identification, and factory technical specifications
- Engine block, crankcase, cylinder head, and main engine assembly components
- Crankshaft, moving parts, and lower-end engine components
- Timing, valve adjustment, and mechanical synchronization
- Diesel injection system and related inspection procedures
- Air filter, intake system, and turbocharger
- Accessory belt drives, intake and exhaust manifolds, and emission control
- Engine electrical system
- Lubrication, cooling, engine mounts, and accelerator control
- Fuel system and exhaust system
Mercedes-Benz models equipped with the OM617.95 Turbo Diesel engine
- W116 Series: 300 SD
- W123 Series: 300 TD, 300 D, and 300 CD
- W126 Series: 300 SD
Important: This is a reference list based on the applications indicated in the manual. Differences may exist depending on model year, market, chassis, and specific vehicle configuration.
Item details:
- Format: PDF
- Language: English
- Pages: 567
- File size: 73.1 MB
- Delivery: Instant Download
Thanks to its technical approach and the level of detail provided in the procedures, this digital edition is especially useful for workshops, restorers, experienced mechanics, and owners who need to consult specific values, sequences, and operations without relying on an original printed copy.
Frequently asked questions about the Mercedes-Benz OM617.95 Turbo Diesel engine manual
Which engine codes are included in this edition?
This edition covers service information for engines 617.950, 617.951, 617.952, and 617.962, all corresponding to variants of the OM617.95 Turbo Diesel.
Does it include information on the turbocharger, intake system, and diesel injection?
Yes. The manual includes content on the injection system, air filter, intake system, and turbocharger, together with related inspection and adjustment procedures.
Does it include procedures for checking compression, cylinder leakage, and oil consumption?
Yes. The content includes diagnostic procedures such as compression pressure testing, checking for cylinder leakage, and measuring oil consumption, among other service operations.
Does it also cover timing, cylinder head, and crankshaft work?
Yes. The manual includes technical information on the cylinder head, crankshaft, internal engine components, timing, and valve train adjustment.
Is it only useful for W116, W123, and W126 models?
The content is oriented to those series, which are the applications explicitly identified in the manual. Even so, it can also serve as a technical reference for other configurations based on the OM617 turbo, provided compatibility is verified.
Is it useful only for major repairs?
No. In addition to teardown and repair procedures, it also includes technical data, capacities, checks, adjustments, and operations that are useful for maintenance, tuning, and general mechanical follow-up.
Mercedes-Benz OM617.95 Turbo Diesel Engine Manual | Index
This index lists the main sections and job numbers included in the Mercedes-Benz Service Manual Engine 617.95 Turbo Diesel
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 Evaluation of cylinder bores
- 01-025 Measuring oil consumption
- 01-030 Removal and installation of engine (oil capacity)
- 01-040 Engine breather - functional description
- 01-110 Measuring, boring and honing 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 for main oil ducts
- 01-140 Replacing core hole closing cover in cylinder crankcase
- 01-215 Removal and installation of front cylinder crankcase cover
- 01-220 Installation and centering of intermediate flange
- 01-310 Removal and installation of complete oil pan
- 01-405 Cylinder head and tightening of cylinder head bolts
- 01-415 Removal and installation of cylinder head
- 01-417 Removal and installation of pre-chambers
- 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 rod
- 03-316 Removal and installation of pistons
- 03-318 Checking and reconditioning of crankshaft
- 03-320 Mounting of crankshaft
- 03-324 Renewing front crankshaft radial sealing ring
- 03-327 Renewing rear crankshaft radial sealing ring
- 03-340 Removal and installation of pulley, vibration damper and balancing disc
- 03-344 Static balancing of balancing disc
- 03-345 Checking and correcting adjustment of TDC transmitter
- 03-350 Removal and installation of crankshaft sprocket
- 03-410 Removal and installation of flywheel and driven plate
- 03-430 Renewing ring gear of flywheel
- 03-440 Statically balancing of flywheel
- 03-450 Instructions for full balancing of engine
05 Engine timing, valves
- 05-210 Inspection and adjustment of valve clearance
- 05-215 Inspection and adjustment of camshaft timing
- 05-220 Removal and installation of camshaft
- 05-225 Grinding camshaft bearing journals
- 05-235 Removal and installation of rocker arms with rocker arm bearing brackets
- 05-240 Renewal of rocker arms and rocker arm bearing brackets
- 05-250 Removal and installation of valve springs
- 05-260 Checking valve springs
- 05-270 Replacement of valve stem seals
- 05-280 Checking and machining valves
- 05-285 Checking and renewing valve guides
- 05-291 Machining valve seats
- 05-310 Removal and installation of chain tensioner
- 05-320 Renewing timing chain
- 05-330 Removal and installation of tensioning rail
- 05-340 Removal and installation of slide rails
- 05-412 Removal and installation of intermediate sprocket shaft
- 05-440 Removal and installation of guide wheel
07.1 Injection system
- 07.1-001 Survey model - engine - injection pump
- 07.1-010 Operation injection pump with governor
- 07.1-015 Operation engine-transmission-overload protection
- 07.1-100 Adjustment of idle speed and idle speed adjuster
- 07.1-105 Checking maximum speed at no-load
- 07.1-108 Checking injection timing (begin of delivery) with digital tester (RIV method)
- 07.1-109 Checking injection timing (begin of delivery) (high pressure method)
- 07.1-110 Checking injection timing (begin of delivery) (flow pressure method)
- 07.1-111 Checking injection timing (begin of delivery) (position indicator RIV method)
- 07.1-114 Adjusting injection timing (begin of delivery) with digital tester (RIV method) - following checkup
- 07.1-115 Adjusting injection timing (begin of delivery) (high pressure method) - following checkup
- 07.1-116 Adjusting injection timing (begin of delivery) (position indicator RIV method) - following checkup
- 07.1-135 Checking injection nozzles
- 07.1-137 Disassembly, cleaning, assembly and adjustment of injection nozzles
- 07.1-140 Venting Injection System
- 07.1-145 Checking fuel pump and bypass valve
- 07.1-150 Checking vacuum shutoff for leaks
- 07.1-200 Removal and installation of injection pump
- 07.1-201 Installation of injection pump (with locking screw)
- 07.1-210 Replacement of pipe connection, delivery valve or copper sealing ring
- 07.1-220 Replacement of vacuum control unit at injection pump
- 07.1-230 Removal and installation of injection nozzles
- 07.1-235 Removal and installation of fuel pump
- 07.1-240 Removal and installation of injection timing device
09 Air cleaner, exhaust gas turbocharger
- 09-400 Removal and installation of air filter
- 09-425 Checking boost pressure of turbocharger
- 09-430 Removal and installation of exhaust gas turbocharger
- 09-450 Functional description of exhaust gas turbocharger with aneroid compensator
13 Belt drives
- 13-335 Instructions concerning renewal and tensioning of V-belts
- 13-340 Renewing and tensioning of V-belt
14 Intake manifold, exhaust manifold, emission control system
- 14-001 Vehicle identification
- 14-050 Operation exhaust gas recirculation (USA)
- 14-100 Testing EGR
- 14-450 Removal and installation of intake manifold, replacement of gasket
- 14-470 Removal and installation of exhaust manifold
15 Electrical system, engine
- 15-705 Operation of preglow system
- 15-708 Installing preglow time relay with modified ventilation
- 15-710 Checking preglow system
18 Engine lubrication
- 18-005 Oil circuit, oil pressure, pressure relief valve and oil filter
- 18-031 Removal and installation of oil return flow line of exhaust gas turbocharger
- 18-040 Removal and installation of oil spray nozzles
- 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 - antifreeze table
- 20-015 Cleaning cooling system
- 20-110 Removal and installation of coolant thermostat
- 20-210 Removal and installation of coolant pump
- 20-220 Reconditioning of coolant pump
- 20-225 Sealing coolant pump
- 20-230 Removal and installation of coolant pump housing
- 20-310 Viscofan coupling, temperature-controlled
- 20-420 Removal and installation of radiator
- 20-425 Reconditioning of radiator
- 20-430 Checking of expansion tank closing cover
- 20-490 Illustrated table thermostat layout
22 Engine suspension
- 22-211 Removal and installation of front engine mounts
- 22-212 Removal and installation of rear engine mount
- 22-220 Adjusting engine stop - Model 123.193
- 22-240 Removal and installation of engine shock absorber
30 Throttle control
- 30-300 Adjusting throttle linkage
- 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
47 Fuel system
- 47-700 Removal and installation of fuel tank
- 47-705 Removal and installation of fuel expansion tank
- 47-710 Removal and installation of immersion tube indicator
- 47-715 Operation of immersion tube indicator for fuel gauge
- 47-720 Operation fuel tank positive and negative venting system
49 Exhaust system
- 49-100 Removal and installation of exhaust system
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Workshop manual for the Mercedes-Benz OM617.95 Turbo Diesel 5-cylinder inline 3.0-liter diesel engine
Includes factory technical information for diagnosis, inspection, disassembly, measurement, adjustment and repair, covering 617.950, 617.951, 617.952 and 617.962 engines from the W116, W123 and W126 series, and useful as a workshop reference for maintenance, restoration and service work on OM617 turbo diesel applications.
PDF in English | 567 pages | Instant Download.
- Technical data, service specifications and filling capacities
- Inspection, disassembly, measurement, adjustment, assembly and repair procedures
- Coverage of cylinder head, crankshaft, valve timing, diesel injection and turbocharger systems
- Useful reference for repair, maintenance and restoration of the OM617 turbo diesel engine