Mercedes Benz Classics: Owners Operation, Service, and Repair Workshop Manuals

Mercedes OM602 OM603 Engine Manual

The Mercedes Benz OM602 OM603 Diesel Engines 1984 to 1999


Download: Mercedes OM602 OM603 Engine Service Repair Manual

Mercedes OM602 OM603 Engine ManualDiesel OM602 OM603 Engine Manual
Download: 78.5mb, 940 pages, .pdf
OM602 Application: W124, W201, W460, W461, W463
OM603 Application: W124, W126, W140, W463

Delivery By Download Link:

Sent to your PayPal email address: $19.95


The Mercedes OM602 engine is a 5-cylinder diesel engine of 2.5 or 2.9 L (2,497 or 2,874 cc). The 2.9 L (2,874 cc) was used in the 310D and 410D Mercedes-Benz T1 and the Phase 1 Mercedes-Benz Sprinter vans (where it was modified for direct injection), the Ssangyong Musso and Korando range and even in the 1996–1999 models of the E-class. It was available in either naturally aspirated or turbocharged variants with two valves per cylinder.

Mercedes OM603 Engine Service Repair Manual

The camshafts and injection pump are driven by duplex chain from the crankshaft. A separate single-row chain drives the oil pump. The camshaft operated the valves via hydraulic bucket tappets; valve clearance adjustment is automatic. On many OM602 engines fuel injection is indirect. A Bosch PES in-line injection pump is used, with a mechanical governor and vacuum-operated stop control. The pump is lubricated by a connection to the engine oil circulation and the fuel lift pump is mounted on the side of the injection pump.

The Mercedes OM603 engine was a straight-6 Diesel automobile engine from Mercedes-Benz used from 1984 through 1999. The 603 saw limited use in the W124, W126 and W140 model vehicles.

The 603.96 engine has a capacity of 2996cc and was an engineering marvel in pre-chamber design and a technological leap forward from the earlier 5 cylinder OM617. It produced 143 hp at 4600 rpm (euro market without catalytic converter produced 148hp) and 195 ft.lb at 2400 rpm with a compression ratio of 22.0:1. Versions 603.96x and 603.97x are turbocharged. Only turbocharged models of the 603 series were available to the U.S. market. The single camshaft and injection pump are driven by duplex chain from the crankshaft. A separate single row chain drives the oil pump. The camshaft operated the valves via hydraulic bucket tappets; valve clearance adjustment is automatic..

Mercedes ON602 and OM603 Engine Service Repair Manual

Version Application Survey OM602 Engines

Mercedes OM602 5-cylinder diesel engine

Model indication Year Engine no OM602...
OM 602.xxx (5-cylinder diesel)
W201 190 2.5 D & W124 250 D 04/1985 - 06/1993 .911 & .912 & .930 & .931
G-Class 250 GD 4x4 .938 & .939
T1 210 & 310 & 410 2.9 D. 10/1988 - 1995 .940 & .942
G-Class 290 GD 4x4 .946 & .947
W201 190D 2.5 Turbo
W124 250D Turbo / 300D 2.5 Turbo
01/1987 - 1996 A.961 & A.962
Sprinter 2,5 Turbo-D. A.963
212D & 312D & 412D & Sprinter 2.9 TD 02/1995 - 04/2000 A.980 & A.986
G-Class 290 GD turbodiesel 4x4 07/1997 - 09/2000 A.983
W210 E290 turbodiesel 03/1996 - 07/1999 A.982

Version Application Survey OM603 Engines

Mercedes OM603 6-cylinder diesel engine

Model indication Year Engine no OM603...
OM 603.xxx (6-cylinder diesel)
W124 300 D 04/1985 - 06/1993 .912
W124 300D Turbo 01/1987 - 03/1996 .960 & .963 (4Matic)
W124 300TD Turbo 1987 .960
W126 300SDL 02/1985 - 09/1987 .961
W126 350SD/SDL 06/1990 - 08/1991 .97x
W140 300SD / S350 09/1991 - 08/1996 .97x