The Mercedes-Benz OM 616.916 is a 2,996 cc, inline-four, turbocharged diesel engine produced between 1999 and 2006. It was designed for commercial and compact executive applications, featuring a Bosch VP44 rotary injection pump and a KKK K16 turbocharger. Delivering 80 kW (109 PS) and 270 Nm, it offered reliable low-end torque suitable for urban delivery and light-duty use.
Fitted primarily to the W203 C-Class and Vito (W639) models, the OM 616.916 was engineered for durability and serviceability in mixed-use environments. It met Euro 3 emissions standards through optimized combustion and mechanical fuel control, without requiring DPF systems in early builds. This engine represented a compact, efficient evolution of Mercedes-Benz's inline-four diesel architecture for entry-level platforms.
One documented concern involves the high-pressure fuel pump, which in early production units may experience internal wear due to lubricity issues with ultra-low-sulfur diesel (ULSD). This issue, highlighted in Daimler Service Information Bulletin 14-05-99, is linked to the Bosch VP44 pump's sensitivity to fuel quality. A revised pump calibration and fuel system upgrade were issued to address long-term reliability.
Production years 1999–2003 meet Euro 3 standards; 2004–2006 models may have enhanced emissions calibration depending on market (VCA UK Type Approval #VCA/EMS/5684).
The Mercedes-Benz OM 616.916 is a 2,996 cc inline-four turbocharged diesel engine engineered for compact sedans and light commercial vans (1999–2006). It combines a robust cast-iron block with a KKK K16 turbocharger and Bosch VP44 rotary injection pump to deliver responsive low-RPM performance and mechanical resilience. Designed to meet Euro 3 standards, it emphasizes durability and ease of service in high-mileage applications.
| Parameter | Value | Source |
|---|---|---|
| Displacement | 2,996 cc | |
| Fuel type | Diesel | |
| Configuration | Inline-4, SOHC, 8-valve | |
| Aspiration | Turbocharged | |
| Bore × stroke | 98.0 mm × 98.6 mm | |
| Power output | 80 kW (109 PS) @ 3,800 rpm | |
| Torque | 270 Nm @ 1,600 rpm | |
| Fuel system | Bosch VP44 rotary injection pump (mechanical-electronic hybrid) | |
| Emissions standard | Euro 3 | |
| Compression ratio | 21.0:1 | |
| Cooling system | Water-cooled | |
| Turbocharger | KKK K16 turbocharger | |
| Timing system | Chain-driven (service interval: 200,000 km) | |
| Oil type | MB 229.3 (SAE 5W-40) | |
| Dry weight | 185 kg |
The turbocharged inline-four layout provides strong low-RPM torque ideal for stop-start urban driving and light load-carrying. The timing chain requires inspection at 200,000 km per Daimler TIS B30566. MB 229.3 (5W-40) oil is essential to protect the high-load VP44 injection pump and turbocharger bearings. Early production units may benefit from a fuel system inspection if operated on low-quality diesel; Bosch VP44 pumps are sensitive to contamination. No DPF in early models simplifies maintenance, but later builds may feature basic EGR; fuel quality is critical to prevent pump failure.
Oil Specs: Requires MB 229.3 (5W-40) specification (Daimler SIB 14-05-99). Compatible with ACEA B4/B5.
Emissions: Euro 3 certification applies to all models (1999–2006) (VCA Type Approval #VCA/EMS/5684). Market-specific variants may include EGR for enhanced compliance.
Power Ratings: Measured under DIN 70020 standards. Output consistent across production run with no significant market variants.
Daimler Technical Information System (TIS): Docs B30566, B31251, SIB 14-05-99
VCA Type Approval Database (VCA/EMS/5684)
SAE International: DIN 70020 Engine Power Testing Standard
The Mercedes-Benz OM 616.916 was used across Mercedes-Benz's W203 and W639 platforms with transverse mounting and shared architecture. This engine received platform-specific adaptations-reinforced mounts in the W639 and compact accessory drives in the W203-and from 2004 the facelifted W203 models adopted revised EGR routing, creating minor interchange limits. All adaptations are documented in OEM technical bulletins.
Locate the engine code stamped vertically on the right-side engine block near the oil filter housing (Daimler TIS B30795). The 8th VIN digit indicates engine type ('M' for OM 616 series). Pre-2004 W203 models have silver valve covers with black plastic timing covers; post-2004 units use all-black covers. Critical differentiation from naturally aspirated variants: OM 616.916 features a KKK K16 turbocharger and VP44 injection pump with electronic control unit. Service parts require production date verification - fuel pumps for engines before 06/2001 are incompatible with later units due to calibration updates (Daimler SIB 14-05-99).
The OM 616.916's primary reliability risk is high-pressure fuel pump wear in early production units, with elevated incidence in models produced before mid-2001. Daimler field reports from 2003 indicated a notable share of W203 C 220 CDI units requiring VP44 pump replacement before 150,000 km, while UK DVSA records show moderate EGR-related failures due to carbon buildup in city-driven vehicles. Extended service intervals and use of non-specification diesel increase pump degradation risk, making preventive maintenance critical.
Analysis derived from Daimler technical bulletins (1999-2007) and UK DVSA failure statistics (2002-2014). Repair procedures should follow manufacturer guidelines.
Find answers to most commonly asked questions about MERCEDES-BENZ OM616916.
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DVLA: Engine Changes & MoT
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Regulation (EC) No 715/2007
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Commission Regulation (EU) 2017/1151
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