Mercedes-Benz OM602 engine

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Mercedes-Benz OM602 Diesel Engine
Motor Om 602 982.jpg
Overview
ManufacturerDaimler-Benz
Production1985 to 2002
Layout
ConfigurationStraight-5
Displacement2.5 L (2,497 cc)
2.9 L (2,874 cc)
ValvetrainSOHC 2 valves x cyl.
Combustion
TurbochargerOn some versions
Fuel systemIndirect injection
Direct injection
ManagementBosch PES in-line or VE-style rotary distributor injection pumps
Fuel typeDiesel
Cooling systemWater-cooled
Output
Power output66–95 kW (90–129 PS; 89–127 hp)
Chronology
SuccessorOM605

The successor of the OM617 engine family was the newly developed straight-5 diesel automobile engine OM602 from Mercedes-Benz used from 1980s up to 2002. With some Mercedes-Benz 250D/E250D diesels exceeding 500,000 or 1,000,000 miles (800,000 or 1,610,000 km), it is considered to be one of the most reliable engines ever produced, a success which is only comparable with the famous OM617 engine.

The 5-cylinder OM602 was succeeded by the four-valve engine OM605 (E250D 20V) and later the OM612 and OM647 with turbocharger and common rail direct injection (C/E/ML 270CDI).

The engine[edit]

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.

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.

Some later versions of the 2.9 L (2,874 cc) capacity unit use a Bosch VE-style rotary distributor injection pump with electronic control and have a significantly different combustion chamber as they use direct injection.

Preheating is by glow plugs with automatic control of preheating time.

Versions of OM602 Mercedes 5-cylinder diesel engine[edit]

Model indication Year Engine no OM602... Power
OM 602.xxx (5-cylinder diesel)
W201 190 2.5 D & W124 250 D 04/1985 - 06/1993 .911 & .912 & .930 & .931 66 kW (90 PS; 89 hp) (<'89) or 69 kW (94 PS; 93 hp) (>'89)
G-Class 250 GD 4x4 .938 & .939
T1 210 & 310 & 410 2.9 D. 10/1988 -> 1995 .940 & .942 72 kW (98 PS; 97 hp) or 75 kW (102 PS; 101 hp)
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 90 kW (122 PS; 121 hp) (<'88) or 92 kW (125 PS; 123 hp) (>'88)
Sprinter 2,5 Turbo-D. A.963
212D & 312D & 412D & Sprinter 2.9 TD 02/1995 -> 04/2000 A.980 & A.986 90 kW (122 PS; 121 hp)
G-Class 290 GD turbodiesel 4x4 07/1997 -> 09/2000 A.983 88 kW (120 PS; 118 hp)
W210 E290 turbodiesel 03/1996 -> 07/1999 A.982 95 kW (129 PS; 127 hp)