602.961 engine — Mercedes-Benz 2.5 CDI (2.5L)
2.5L · 122 hp
Engine overview
Vehicles with this engine
Factory specifications
Values from the manufacturer documentation for this engine.
Engine (general)
| Engine code | 602.961 |
| Capacity | 2497 cc |
| Idle speed | 610 - 810 rpm |
| Normal | 26.0 - 32.0 bar |
| Minimum | 18.0 bar |
| Differential limit between cylinders | 3.0 bar |
| Oil pressure | 3/3000 bar/rpm |
Engine (diesel)
| Injection pump (make and type) | Bosch PES 5M 55C 320RS 158-1 |
| Number of cylinders | 5 |
| Injector firing order | 1-2-4-5-3 |
| Injector pressure | 135 - 145 bar |
| Minimum | 120 bar |
| Coolant temperature during test | 70 °C |
| Idle speed, minimum | 610 rpm |
| Idle speed, maximum | 810 rpm |
| Min. no-load governed speed | 4900 rpm |
| Max. no-load governed speed | 5400 rpm |
| Exhaust gas analysis | < 2.50 m-1 |
| Exhaust gas analysis (opacity) | 66 % |
| Exhaust gas analysis test method (Germany only) | B |
| Test time | 1 s |
Cooling system
| Cap pressure | 1.4 bar |
| Thermostat opens at | 78 - 82 °C |
Electrical
| Battery | (- 08/1991): 72 (- 10/1992): 92 (11/1992): 74 Ah |
| Alternator | 55 A |
Capacities
| Engine sump, incl. filter | 7.0 l |
| Gearbox refill | 1.5 l |
| Gearbox refill | 6.0 l |
| Differential | 1.1 l |
| Cooling system | 8.0 l |
Torque settings
| Cylinder head bolts — Stage 1 | 15 Nm |
| Cylinder head bolts — Stage 2 | 35 Nm |
| Cylinder head bolts — Stage 3 | 90 ° |
| Cylinder head bolts — Stage 5 | 90 ° |
| Cylinder head bolts — Stage 1 | 25 Nm |
| Rear hub | 280 - 320 Nm |
| Wheel nuts | 110 Nm |
| Glow plugs | 20 - 22 Nm |
Workshop procedures for this engine
Step-by-step procedures from the workshop database.
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Get free diagnosis →Who makes these pages, and how
TorqFix was built by a mechanic — after a 2,700 km drive with five roadside repairs that no diagnostic tool could explain.
The figures on this page come from manufacturer workshop documentation and are shown as they are. The page is assembled automatically from that data — it is not written by an AI. The AI works in the chat, where it answers for your specific car. It writes nothing here.
Variants of the same model differ. Cross-check torque against the factory manual for your engine before final tightening.
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The story behind TorqFix →Workshop data on this page last updated 22 Aug 2026.