Overhauling the OM 602 and 603 Turbo Chargers

Sep 5, 2020


Welcome to Grafco Electric's comprehensive guide on overhauling the OM 602 and 603 turbo chargers. In this detailed guide, we will walk you through the step-by-step process of optimizing the performance of these turbochargers. Whether you are a seasoned mechanic or a DIY enthusiast, this guide is designed to provide you with all the information you need to know to achieve optimal results.

Understanding Turbochargers

Before diving into the overhaul process, it's essential to have a solid understanding of how turbochargers work. Turbochargers are a critical component of modern engine systems, improving efficiency and power output. They achieve this by compressing the air entering the engine, enabling more air and fuel to be burned, resulting in increased performance.

OM 602 and 603 turbochargers are commonly found in Mercedes-Benz vehicles and have their unique set of considerations when it comes to overhauling. Understanding the intricate workings of these turbochargers is crucial for a successful overhaul.

The Overhauling Process

Step 1: Preparation

Begin the overhaul process by gathering all the necessary tools and equipment, ensuring you have a clean and well-lit workspace. It is crucial to have a detailed understanding of the specific model of the OM 602 or 603 turbocharger you are working on, as there might be slight variations in the overhaul process depending on the version.

Step 2: Disassembly

Next, carefully disassemble the turbocharger, starting with the removal of the intake and exhaust components. Pay close attention to the sequence of disassembly and take detailed notes or pictures to assist with reassembly. Inspect each component for any signs of wear or damage that may require replacement.

Step 3: Cleaning and Inspection

Thoroughly clean the disassembled components using appropriate solvents and a soft brush. Take extra care when cleaning delicate parts to avoid any damage. Once cleaned, conduct a close inspection of each part, looking for signs of wear, corrosion, or any other issues that may impact turbocharger performance. Replace any damaged or worn components.

Step 4: Reassembly

When reassembling the turbocharger, ensure all components are correctly aligned and seated. Follow the manufacturer's specifications and torque recommendations for each part. Apply the appropriate lubrication and sealing compounds as necessary. Take your time during this step to ensure everything is accurately assembled.

Step 5: Balancing

Once the turbocharger is reassembled, it is crucial to balance the rotating assembly. Turbocharger balancing helps minimize vibrations and ensures optimal performance. Seek professional assistance or use specialized equipment to achieve the necessary balancing.

Step 6: Installation and Testing

Carefully install the overhauled turbocharger back into the engine, following the manufacturer's installation guidelines. Before starting the engine, carry out a thorough inspection of all connections and ensure everything is properly secured. Once installed, conduct a series of tests to verify proper functionality and performance.


In conclusion, overhauling the OM 602 and 603 turbochargers requires meticulous attention to detail and a comprehensive understanding of the process. By following the steps outlined in this guide, you will be well-equipped to achieve optimal performance from these turbochargers. Remember to exercise caution, patience, and precision throughout the entire overhaul process. If you encounter any difficulties, it is advisable to seek professional assistance.

For any further questions or assistance regarding the overhaul process of OM 602 and 603 turbochargers, do not hesitate to reach out to Grafco Electric's expert team. Our knowledgeable professionals are always ready to provide guidance and support to ensure your turbocharger overhaul is a success.

Paula James
Great guide for turbo charger!
Nov 11, 2023