Mercedes-Benz OM601 Diesel Engine Service Manual 6510 1921 13 PDF

Description

Mercedes-Benz OM601 Diesel Engine Service Manual 6510 1921 13 PDF DOWNLOAD

DESCRIPTION:

This comprehensive Mercedes-Benz OM601 diesel engine service manual (Publication 6510 1921 13) provides complete factory technical documentation for servicing, repairing, and overhauling Mercedes-Benz OM601 series diesel engines. Essential for Mercedes-Benz diesel mechanics, independent repair shops, and automotive technicians working on classic Mercedes diesel vehicles.

Engine Applications:

The OM601 diesel engine is found in various Mercedes-Benz models including:

W201 Chassis (190 Series):

• Mercedes-Benz 190D (OM601 2.0L diesel)
• Mercedes-Benz 190D 2.5 (OM602 variant)

W124 Chassis (E-Class):

• Mercedes-Benz 200D (OM601 2.0L diesel)
• Mercedes-Benz 250D (OM602 2.5L diesel)
• Mercedes-Benz E200 Diesel

Other Applications:

• W123 series diesel models
• Various commercial vehicle applications
• Industrial and marine diesel conversions

The OM601 is a legendary Mercedes-Benz inline diesel engine known for exceptional durability, reliability, and longevity – frequently exceeding 300,000+ miles with proper maintenance.

Manual Organization:

This service manual follows the Mercedes-Benz Component Group System for easy navigation:

GROUP INDEX – Major Component Groups:

GROUP 00 – GENERAL, TECHNICAL DATA

• Instructions for use of service manual
• Engine and vehicle identification procedures
• Vehicle identification number (VIN) locations
• Technical data and specifications for all OM601 variants
• Engine displacement, bore, stroke, compression ratio
• Power output and torque specifications
• Oil capacity and coolant capacity
• Clearances and tolerances
• Torque specifications reference

GROUP 01 – CRANKCASE AND CYLINDER HEAD

• Cylinder head removal and installation procedures
• Cylinder head gasket replacement
• Valve cover removal and gasket service
• Cylinder head disassembly and assembly
• Cylinder head inspection and reconditioning
• Valve guide replacement procedures
• Valve seat reconditioning and machining
• Cylinder head warpage measurement
• Prechamber (swirl chamber) service for indirect injection
• Piston and connecting rod removal and installation
• Piston ring installation and gap measurement
• Cylinder bore measurement and honing
• Crankcase inspection procedures
• Oil pan removal and gasket replacement

GROUP 03 – CRANKSHAFT ASSEMBLY

• Crankshaft removal and installation
• Crankshaft journal measurement
• Main bearing replacement procedures
• Connecting rod bearing service
• Crankshaft end play adjustment
• Flywheel and ring gear service
• Rear main seal replacement
• Harmonic balancer/vibration damper service
• Crankshaft pulley removal and installation

GROUP 05 – ENGINE TIMING, VALVES

• Timing chain removal and installation
• Timing chain tensioner adjustment
• Camshaft removal and installation procedures
• Camshaft bearing inspection
• Camshaft lobe measurement and wear limits
• Valve adjustment procedures and specifications
• Valve clearance measurement (hot and cold)
• Rocker arm assembly service
• Valve spring inspection and replacement
• Valve stem seal replacement
• Timing gear alignment marks
• Valve timing procedures

GROUP 07.1 – INJECTION SYSTEM

• Fuel injection pump removal and installation
• Injection pump timing procedures
• Fuel injector removal and testing
• Injector nozzle testing and specifications
• Injection line replacement
• Fuel delivery valve service
• Governor adjustment procedures
• Idle speed adjustment
• Maximum speed (high idle) adjustment
• Injection pump drive gear service
• Glow plug system service
• Cold start system operation

GROUP 09 – AIR CLEANER

• Air cleaner assembly removal
• Air filter element replacement
• Air intake system inspection
• Intake hose and connection service

GROUP 13 – BELT DRIVE

• Serpentine belt removal and installation
• V-belt replacement procedures
• Belt tension adjustment specifications
• Pulley alignment inspection
• Idler pulley and tensioner service

GROUP 14 – INTAKE MANIFOLD, EXHAUST MANIFOLD, EMISSION CONTROL SYSTEM

• Intake manifold removal and installation
• Intake manifold gasket replacement
• Exhaust manifold removal and service
• Exhaust manifold stud replacement
• Turbocharger service (if equipped on variants)
• EGR system service (emissions-equipped models)
• Emission control component inspection

GROUP 15 – ELECTRICAL SYSTEM, ENGINE

• Alternator removal and installation
• Alternator belt adjustment
• Starter motor removal and testing
• Starter solenoid replacement
• Glow plug removal and testing
• Glow plug relay and timer service
• Engine wiring harness inspection
• Electrical connector service
• Sensor testing procedures

GROUP 18 – ENGINE LUBRICATION

• Oil pump removal and installation
• Oil pump clearance measurement
• Oil pressure relief valve service
• Oil filter housing service
• Oil cooler inspection (if equipped)
• Crankcase ventilation system
• Oil dipstick tube replacement
• Lubrication system diagnosis

GROUP 20 – ENGINE COOLING

• Water pump removal and installation
• Thermostat replacement and testing
• Radiator removal and service
• Cooling fan and clutch service
• Coolant hose replacement
• Heater core connections
• Cooling system pressure testing
• Coolant temperature sensor replacement

GROUP 22 – ENGINE SUSPENSION

• Engine mount removal and replacement
• Transmission mount service
• Engine mounting bracket inspection
• Torque mount (dog bone) replacement

GROUP 30 – THROTTLE CONTROL

• Accelerator cable adjustment
• Throttle linkage service
• Cruise control cable adjustment (if equipped)

GROUP 47 – FUEL SYSTEM

• Fuel tank removal and installation
• Fuel pump replacement (mechanical lift pump)
• Fuel filter replacement procedures
• Fuel lines and connections
• Fuel supply system inspection
• Fuel return system service
• Fuel tank sender unit service

GROUP 49 – EXHAUST SYSTEM

• Exhaust pipe removal and installation
• Muffler replacement
• Catalytic converter service (emissions models)
• Exhaust hanger replacement
• Exhaust system leak diagnosis

Key Features of This Service Manual:

✓ Original Mercedes-Benz factory documentation from MBNA ✓ Detailed removal, disassembly, assembly, and installation procedures ✓ Comprehensive torque specifications for all fasteners ✓ Inspection standards and wear limits ✓ Adjustment procedures with specifications ✓ Exploded diagrams and component identification ✓ Special tool identification and part numbers ✓ Troubleshooting and diagnostic procedures ✓ Complete OM601 diesel engine overhaul instructions ✓ Fuel injection pump timing and adjustment ✓ Valve adjustment procedures ✓ Professional Mercedes-Benz service standards

Technical Highlights:

OM601 Engine Characteristics:

• Engine Type: Inline 4-cylinder or 5-cylinder (depending on variant)
• Displacement: 2.0L to 2.5L
• Fuel System: Indirect injection diesel (prechamber/swirl chamber)
• Valve Configuration: SOHC (Single Overhead Camshaft)
• Cooling: Water-cooled
• Known For: Extreme durability and longevity (300,000-500,000+ miles common)
• Applications: Passenger cars, taxis, commercial vehicles

Applications:

This Mercedes-Benz OM601 service manual is essential for:

• Mercedes-Benz diesel specialists
• Independent auto repair shops
• Classic Mercedes restoration shops
• Diesel engine rebuild specialists
• Fleet maintenance operations
• Technical training schools
• DIY Mercedes diesel enthusiasts
• Taxi and commercial vehicle operators

Ideal For:

• Professional Mercedes-Benz technicians
• Independent diesel mechanics
• Classic car restoration specialists
• Mercedes-Benz enthusiasts and DIY mechanics
• Automotive technical students
• Fleet maintenance managers
• Mobile diesel repair services

This comprehensive factory service manual provides the complete technical knowledge required to properly maintain, diagnose, and repair the legendary Mercedes-Benz OM601 diesel engine, ensuring optimal performance and extending the already impressive service life of these renowned engines.

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