1987-1996 Mercedes-Benz OM602, OM603 Engines OEM Service & Repair Manual

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

1987-1996 Mercedes-Benz OM602, OM603 Engines OEM Service & Repair Manual

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