Has anybody recently replaced an engine stop diaphragm on an OM602 (2.5 lt 5 cyl) injection pump? Any tips for removing the air intake manifold and replacing the diaphragm?

Yes, that job has been done many times and many folks have posted about it.

Use the search function in google and find the multitude of posts on the topic. The 603 is the more common engine..........the procedure is going to be very similar.

Many people have posted their shut off problems in the past, and have gotten a variety of responses related to vacuum pumps, lines, leaks, and ignition switch issues. I know that my diaphragm needs replacing. I haven't yet seen a post detailing or giving advice on how to complete the repair on an OM602.

Point me in the right direction?

I took a quick look and also didn't find any specific writeup on either the 602 or the 603.

Apparently, it's a straightforward change once the manifold is removed.

One of the folks who have done it will post on the procedure.

The manifold is easy, 6mm (I think) hex.
It looked like 1 bolt and the stop mechanism would come off/out, when I had my intake off a few weeks ago. Of course I didn't do it, my car shuts off fine and no need to disturb it.

1. remember to align the glowplug channel with the manifold when you put it back on, if you don't your throttle linkage won't move properly and stick in WOT the first time you put it there.
2. if you drop a bolt it is sitting behind the IP or a nice ledge on the block, so no need to remove the belly pan

Also I sent you a link to the PDF manual for the W201.

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pdrayton had an EXCELLENT post a while back about this.

http://www.peachparts.com/shopforum/showthread.php?t=190780

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