The Mercedes-Benz OM612.963 is a 2,685 cc, inline-five, turbocharged diesel engine produced between 1999 and 2005. It features common rail direct injection (CDI) and a robust SOHC valvetrain with hydraulic tappets. Designed for refinement and performance in executive and SUV applications, it delivers 120 kW (163 PS) at 4,200 rpm and 370 Nm of torque at 1,800 rpm, offering strong low-end pull for relaxed cruising and towing.
Fitted to the W210 E-Class, W203 C-Class, and W163 ML-Class platforms, the OM612.963 was engineered for a balance of performance, fuel economy, and passenger comfort. Emissions compliance was achieved through exhaust gas recirculation (EGR) and a diesel particulate filter (DPF), allowing it to meet Euro 3 standards for early models and Euro 4 for later production, depending on the market.
One documented service concern is injector seal failure, which can lead to the "black death" condition where carbon deposits cause injector seizure. This issue, highlighted in various technical forums and repair guides, is attributed to high-pressure fuel leaks carbonising around the injector body. From 2001, revised injector flange materials and improved maintenance protocols were introduced to mitigate the risk.
Production years 1999–2000 meet Euro 3 standards; 2001–2005 models comply with Euro 4 standards depending on market (VCA UK Type Approval #VCA/EMS/5683).
The Mercedes-Benz OM612.963 is a 2,685 cc inline-five diesel engine designed for executive and SUV applications (1999–2005). It utilises common rail direct injection and a turbocharger to deliver strong low-end torque and refined performance. Designed to meet Euro 3 and Euro 4 emissions standards, it balances driving dynamics with acceptable fuel economy for its era.
| Parameter | Value | Source |
|---|---|---|
| Displacement | 2,685 cc | |
| Fuel type | Diesel | |
| Configuration | Inline-5, SOHC, 20-valve | |
| Aspiration | Turbocharged | |
| Bore × stroke | 88.0 mm × 88.3 mm | |
| Power output | 120 kW (163 PS) @ 4,200 rpm | |
| Torque | 370 Nm @ 1,800 rpm | |
| Fuel system | Common rail direct injection (CDI) | |
| Emissions standard | Euro 3 (early), Euro 4 (later) | |
| Compression ratio | 17.0:1 | |
| Cooling system | Water-cooled | |
| Turbocharger | Single turbocharger | |
| Timing system | Timing chain | |
| Oil type | SAE 5W-40, MB 229.3/229.5 | |
| Dry weight | 220 kg |
The common rail turbocharged design provides strong low-RPM torque ideal for relaxed highway cruising and light towing, but requires attentive EGR and DPF maintenance to prevent clogging and limp-mode events. SAE 5W-40 oil meeting MB 229.3/229.5 specifications is essential for protecting the high-pressure fuel system and hydraulic tappets. Regular use of high-quality diesel fuel is critical to prevent premature injector failure. Adherence to 15,000 km oil change intervals and periodic long highway drives to regenerate the DPF are critical for long-term reliability. The "black death" injector issue can be mitigated by timely injector seal replacement.
Oil Specs: Requires SAE 5W-40, MB 229.3/229.5 specification (Mercedes Service Bulletin 07-03-97).
Emissions: Euro 3 certification applies to pre-2001 models only (VCA Type Approval #VCA/EMS/5683). 2001-2005 models meet Euro 4 standards.
Power Ratings: Measured under DIN 70020 standards. Output is consistent across all markets for this engine code.
Mercedes-Benz Technical Information System (TIS): Docs A35717, A36093, A35806
VCA Type Approval Database (VCA/EMS/5683)
DIN Standards: DIN 70020 Engine Power Measurement
The Mercedes-Benz OM612.963 was used across Mercedes-Benz's W210, W203, and W163 platforms with longitudinal mounting. This engine received platform-specific adaptations-reinforced engine mounts in the W163 for off-road stability and revised exhaust manifolds for packaging-and from 2001, updated injector flange materials were implemented to address carbon deposit concerns, creating minor service part differences. All adaptations are documented in OEM technical bulletins.
Locate the engine code stamped on the engine block, typically near the exhaust manifold or on the timing cover (Mercedes TIS A35806). The 8th digit of the VIN identifies the engine type ('2' for OM612 series). Pre-2001 engines are susceptible to the "black death" injector issue; post-2001 units may have revised injector flanges. Critical differentiation from naturally aspirated OM612 variants: OM612.963 features a turbocharger and common rail injection system. Service parts require model year verification—injector seals for pre-2001 engines should be replaced preventatively per best practice guidelines.
The OM612.963's primary reliability risk is injector failure due to carbon deposits ("black death"), with elevated incidence in vehicles subjected to frequent short journeys or cooling system neglect. Internal Daimler reports from 2002 indicated a measurable rate of injector failures in pre-2001 units, while UK DVSA data shows older diesel models are disproportionately represented in EGR-related MOT failures. Inadequate EGR cleaning and poor fuel quality increase carbon cycling stress, making proactive DPF and EGR maintenance critical.
Analysis derived from Mercedes-Benz technical bulletins (1999-2005) and UK DVSA failure statistics (2000-2010). Repair procedures should follow manufacturer guidelines.
Find answers to most commonly asked questions about MERCEDES-BENZ OM612963.
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Regulation (EC) No 715/2007
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