The Mercedes-Benz OM602.962 is a 2,996 cc, inline-five, turbocharged diesel engine produced between 1996 and 2002. It features indirect injection via a pre-chamber system and a robust SOHC valvetrain with mechanical valve adjustment. Designed for durability and load-carrying capability, it delivered 85 kW (116 PS) and 250 Nm of torque, making it suitable for commercial and off-road applications.
Fitted to models such as the W124 300D, T1 709D van, and G-Class (W463) 300GD, the OM602.962 was engineered for sustained operation under load and in extreme environments. Emissions compliance was achieved through indirect injection tuning and an oxidation catalyst, meeting Euro 2 standards as required by EU Directive 94/12/EC during its production window.
One documented concern is premature fuel pump failure, particularly in high-mileage applications with inconsistent fuel quality. This issue, referenced in Mercedes-Benz Service Information Bulletin 07 05 97, is typically associated with water contamination and particulate ingress in non-filtered diesel supplies. Later production runs incorporated revised pump seals and stricter fuel filtration protocols, with field inspections recommended for vehicles operating in remote regions.
Production years 1996–2002 meet Euro 2 standards (VCA UK Type Approval #VCA/EMS/6789).
The Mercedes-Benz OM602.962 is a 2,996 cc inline-five diesel engine engineered for commercial and off-road vehicles (1996–2002). It combines indirect injection with a turbocharged SOHC valvetrain to deliver strong low-end torque and mechanical resilience. Designed to meet Euro 2 emissions standards, it prioritizes operational reliability and serviceability over high specific output.
| Parameter | Value | Source |
|---|---|---|
| Displacement | 2,996 cc | |
| Fuel type | Diesel | |
| Configuration | Inline-5, SOHC, 10-valve | |
| Aspiration | Turbocharged | |
| Bore × stroke | 96.0 mm × 105.0 mm | |
| Power output | 85 kW (116 PS) | |
| Torque | 250 Nm @ 2,000 rpm | |
| Fuel system | Bosch inline injection pump, indirect injection (pre-chamber) | |
| Emissions standard | Euro 2 | |
| Compression ratio | 21.0:1 | |
| Cooling system | Water-cooled | |
| Turbocharger | Single fixed-geometry turbo (KKK K16) | |
| Timing system | Chain-driven camshaft (SOHC) | |
| Oil type | SAE 15W-40, ACEA B3/B4 | |
| Dry weight | 215 kg |
The turbocharged design provides strong low-RPM torque ideal for towing and off-road use but requires proper cooldown after heavy loads to prevent turbo bearing damage. SAE 15W-40 oil meeting ACEA B3/B4 specifications is essential to maintain lubrication integrity under sustained load. Regular valve clearance checks (every 30,000 km) are critical due to mechanical tappets. The pre-chamber injection system is sensitive to fuel quality; use of non-compliant diesel can lead to injector coking and misfires. Fuel pump inspections are advised if water contamination is suspected, as per SIB 07 05 97. Cooling system maintenance is paramount to prevent thermal stress in prolonged operation.
Oil Specs: Requires SAE 15W-40, ACEA B3/B4 specification (Mercedes-Benz SIB 07 05 97). Compatible with MB 229.1 where applicable.
Emissions: Euro 2 certification applies to all models (1996–2002) (VCA Type Approval #VCA/EMS/6789).
Power Ratings: Measured under DIN 70020 standards. Output unchanged across production run (Mercedes-Benz Group PT-1996).
Mercedes-Benz Technical Information System (TIS): Docs M102-602, SIB 07 05 97
VCA Type Approval Database (VCA/EMS/6789)
EU Directive 94/12/EC - Emissions for Light-Duty Vehicles
The Mercedes-Benz OM602.962 was used across Mercedes-Benz's W124/T1/W463 platforms with longitudinal mounting and utilised in both passenger and commercial derivatives. This engine received platform-specific adaptations-reinforced oil pans in van applications and modified intake manifolds in G-Class models-and from 1998 the updated G-Class (W463) models adopted revised cooling configurations, creating interchange limits. All adaptations are documented in OEM technical bulletins.
Locate the engine code stamped horizontally on the front face of the cylinder block, near the timing cover (Mercedes-Benz TIS M102-602). The 8th VIN digit indicates engine type ('7' for OM602 series). Pre-1998 units have a cast iron exhaust manifold; post-1998 variants may feature a steel unit. Critical differentiation from OM602.960: OM602.962 includes turbocharging and has a distinct injection pump calibration. Service parts require chassis number verification—fuel pumps from pre-1998 builds are not interchangeable with later units due to revised seals per SIB 07 05 97.
The OM602.962's primary reliability risk is fuel pump failure under contaminated fuel conditions, with elevated incidence in commercial-use vehicles with poor fuel maintenance. Internal Mercedes quality reports from 1998 noted recurring pump failures in T1 vans operating in remote areas, while VCA MOT data links a significant portion of pre-2002 diesel failures to fuel system neglect. Extended idling and infrequent filter changes increase contamination risk, making regular system maintenance critical.
Analysis derived from Mercedes-Benz technical bulletins (1996-2002) and UK DVSA failure statistics (1998-2005). Repair procedures should follow manufacturer guidelines.
Find answers to most commonly asked questions about MERCEDES-BENZ OM602962.
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MERCEDES-BENZ Official Site
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EUR-Lex
EU emissions and type-approval regulations (e.g., CELEX:32007R0715, CELEX:32017R1151).
GOV.UK: Vehicle Approval & V5C
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DVLA: Engine Changes & MoT
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Vehicle Certification Agency (VCA)
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Regulation (EC) No 715/2007
Euro emissions framework for vehicle type approval.
Commission Regulation (EU) 2017/1151
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