1987-1996 Mercedes-Benz OM602 OM603 Engine Service & Repair Manual
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General, technical data 00
Job No.
Instructions for use of service manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 - 005
Engine and vehicle identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 010
Vehicle identification number locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 015
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 020
Instructions for use of servic 00-005
Complete Service Manual coverage for late
model year Mercedes-Benz vehicles requires
four individual manuals:
Service Manual, Engine
Service Manual, Chassis and Body
Service Manual, Automatic Climate Control
Electrical Troubleshooting Manual
Throughout these manuals, the vehicles are
identified by their chassis and engine numbers.
These numbers are made up of the first six digits
of the respective serial number. For the actual
location of chassis and engine numbers, see
page 00-015/l. In cases where the repair
instructions apply to all versions, only the first
three digits of the respective number are
referenced.
For example, chassis 124 applies to all 124
models. However, chassis 124.128 would apply
only to model 3000 2.5 Turbo.
Location of specific repair instructions
First locate the Group No. in the Group Index.
Individual groups are separated by an easily
visible dividing page, which is followed by the job
index page. The exact job required is found in
the job index. The initial page of a typical job
description appears as follows:
03-320 Installation of Crankshaft
Job Title appears on
same line as Group
No.
03.9-320/l
Technical data, tightening torques and tools are
listed at the beginning of each job.
All dimensions are in metric units unless
otherwise indicated. Any part numbers given are
only used for identification and differentiation
between individual components, and are not
intended for ordering purposes.
Special Instructions
AWarning Appears throughout service instructions indicating the possiblity of personal injury
if procedures are not followed.
Caution! Indicates possible equipment or vehicle damage if procedures are not followed.
Note Provides helpful information for the described procedure.
Installation note Provides detailed information during assembly.
00 ngine and vehicle identification
Model
I
Sales designation
I
Engine
201.126 190 D 2.5 602.911
126.125 300 SDL Turbo (Federal) 603.961
126.125 300 SDL Turbo (California) 603.961
201.126 190 D 2.5 602.911
201.128 190 D 2.5 Turbo (Federal) 602.961
124.133 300 D Turbo 603.960
124.193 300TD Turbo 603.960
126.125 300 SDL Turbo 603.961
201.126
I
190 D 2.5 (Federal)
I
602.911
201.126
I
190 D 2.5 (Federal)
I
602.911
124.128 300 D 2.5 Turbo (Federal) 602.962
126.135 350 SDL Turbo (Federal) 603.970
124.128 300 D 2.5 Turbo (Federal) 602.962
126.134 350 SD Turbo (Federal) 603.970
126.135 350 SDL Turbo (Federal) 603.970
00 - 010/l
hick identification number locations
00
Model 201
When ordering spare parts, please
specify chassrs and engine numbers.
Model 124
When ordering spare parts, please
specify chassis and engine numbers.
1 Certrfication Tag (left door pillar)
2 Identification Tag (left windshield post)
3 Vehicle Identificatron No.
4 Engine No.
5 Body No. and Paintwork No.
6 InformatIon Tag
California version
Vacuum line routing for emission
control system
7 Emrsslon Control Tag
1 Certification Tag (left door pillar)
2 Identification Tag (left window post)
3 Vehicle Idenkficatron No.
4 Engine No.
5 Body No. and Paintwork No.
6 lnformatron Tag
California version
Vacuum line routing for emission
control system
7 Emission Control Tag
8 Emrssron Control Tag
Catalyst Information
00 - 015/l
Vehicle identification number locations
Model 124 f
When ordering spare parts, please
specify chassrs and engine numbers.
1 Certrfication Tag (left door prllar)
2 ldentrftcatronTag (left wrndshreld post)
3 Vehicle ldentifrcatron No.
4 Engine No.
5 Body No. and Paintwork No.
6 lnformatron Tag
Caltfornia version
Vacuum line routing for emrssron
control system
7 Emrssron Control Tag
Model 126
When ordenng spare parts, please
specrfy chassis and engine numbers.
Certification Tag (left door pillar)
ldentlficatron Tag (left wrndow post)
Vehicle ldentrfication No.
Engrne No.
Body No. and PaMwork No.
Emrssron Control Tag
lnformatron Tag
California version
Vacuum lrne routing
for emrssron control system
Technical data
Diesel engines
axlmum spee
G(multi-component, 6 (multi-component,
pump, thermosta pump, thermosta
with bypass line, fan with bypass line, fan
with visco fan clutch, with visco fan clutch,
4600 t 50
120/4600
pump, thermosta pump, thermosta
with bypass line, fan with bypass line, fan
with visco fan clutch,
00 - 020/l
00 Technical data
Gasoline engines
Model i 126.125 1126.125 1 126.134 I.135
4-cycle diesel, MB 4-cycle diesel, MB 4-cycle diesel, MB
arranqemen
Bore/stroke mm
I
87.0184.0
I
87.Oi84.0
I
89.0192.4
Total effective
piston
displacement cc
2996 2996
Compression
ratio
Engine output
(SAE)kW/rpm
net bhp/rpm
11 O/4600 1071’4600
14814600 143) 4600
Maximum torque
Nmirpm
net lb-ft./rpm
27312400
20112400
265/2400
195/2400
3 1 o/2000
22812000
Crankshaft
bearings
7 (multi-component, 7 (multi-component, 7 (multi-component,
anti-friction bearings) anti-friction bearings) anti-friction bearings)
Valve
arrangement
Overhead Overhead Overhead
Camshaft
arrangment
1 overhead camshaft 1 overhead camshaft 1 overhead camshaft
Cooling
Coolant circulating
pump, thermostat
with bypass line, fan
with visco fan clutch,
finned tube radiator
Coolant circulating
pump, thermostat
with bypass line, fan
with visco fan clutch,
finned tube radiator
Coolant circulating
pump, thermostat
with bypass line, fan
with visco fan clutch,
finned tube radiator
Lubrication
Pressure lubrication Pressure lubrication
via gear type pump via gear type pump
Combination full flow Combination full flow
1 and bypass filter 1 and bypass filter
Pressure lubrication
via gear type pump
Combination full flow
and bypass filter
Oil filter
Air cleaner
Dry paper cartridge Dry paper cartridge Dry paper cartridge
00 - 02012
Technical data cm
Filling capacities
Model 201.126
I
201.128
(Federal)
124.128
(Federal)
I
124.133,
I
126.125
124.193 (Federal)
Sales designation 190 D 2.5 190 D 2.5
Turbo
300 D 2.5
Turbo
300 D Turbo 300 SDL Turbo
300 TD Turbo
Engine 602.911
-r-m ~
602.961 602.962
I
603.960
I ~~~
603.961
Fuel tank/reserve
aoorox. I
7019.0
I
7019.0
I
90112.5
72/l 0.0
8.2
I
9.2
I
9.2 Engine oil initial filling
approx. I
During oil and filter
change approx. I
Marks on dipstick
max./min. approx. I
Oil-to-air cooler with
hoses
Cooling system with
heater
approx. I
7.0
I
8.0
I
8.0
6.Oi4.0
I
6.5i4.5
I
6.514.5 5.513.5 6.0/4.0
0.7
I
1.1
I
0.65
8.0 8.0 9.0 10.0 12.5
Filling capacities (continued)
~ 350 SDL Turbo
603.970
90/l 2.5
603.961 Engine
Fuel tan k/reserve
approx. I
90/l 2.5
Engine oil initial filling
approx. I
During oil and filter
change approx. I
Marks on dipstick
max./min. approx. I
Oil-to-air cooler with
hoses
8.0 7.5
6.514.5 6.514.5
0.65 0.65
Cooling system with
heater
aoorox. I
00 - 02013
00 Technical data
Electrical system
Model 201.128
(Federal)
124.128
(Federal)
124.133,
124.193
126.125
(Federal)
201.126
190 0 2.5
Turbo
300 D 2.5
Turbo
300 0 Turbo
300 TD Turbo
Sales designation 300 SDL Turbo
602.962 Engine 602.911 602.961 603.960 603.961
Battery
Voltage
Capacity
12v
62 Ah
(M.Y. 1986)
92 Ah (from
M. Y. 1987)
12 v
92 Ah
12v 12v
92 Ah
12v
92 Ah
12V
2.2 kW
12v
1.5 kW
Starter Bosch 12 v
2.2 kW
14V70A 14V70A 14v 80A 14V70A 14V70A Alternator
Electrical system
Model
I
126.125
(California)
126.134.1.135
(Federal)
Sales designation 300SDL Turbo 350 SD Turbo
350 SDL Turbo
603.970
Battery
Voltage
Capacity
12v
62 Ah
12v
62 Ah
Starter Bosch 12 v 12v
2.2 kW 1.7 kW
Alternator
I
14V70A
I
14v 80A
00 - 020/4
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Print one or all pages of your manual
$41.99
Thank you for considering this comprehensive Workshop Service Repair Manual for the Mercedes Benz OM602 OM603 Engine spanning the years 1987 to 1996.
This manual is an invaluable resource for both professional mechanics and DIY enthusiasts, covering every service and repair procedure with easy-to-follow step-by-step instructions and detailed illustrations.
By utilizing this manual, you can significantly reduce expenses by performing your own repairs. It provides the flexibility to print specific pages, chapters, or the entire manual, and can also be saved to a tablet or smartphone for easy access.
All models, engines, trim levels, and transmission types are included in this manual, ensuring comprehensive coverage for a wide range of vehicles.
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