The Mercedes-Benz OM628.960 is a 5,030 cc, V8 turbo-diesel engine produced between 2002 and 2005. It was engineered as a high-torque powerplant for luxury and commercial applications, featuring common-rail direct injection, variable geometry turbocharging (VGT), and DOHC valvetrain architecture. In standard tune it delivered 165 kW (224 PS) and 510 Nm of torque, enabling strong low-end response suitable for heavy-duty use.
Fitted primarily to the W220 S-Class (S 320 CDI) and V221 CL-Class, the OM628.960 was designed to balance refined cruising performance with robust diesel efficiency. Emissions compliance was achieved through cooled exhaust gas recirculation (EGR) and oxidation catalyst technology, meeting Euro 3 standards across all production years. Its smooth power delivery and quiet operation made it a flagship diesel offering in premium segments.
One documented reliability concern involves high-pressure fuel pump (HPFP) degradation, particularly in units subjected to extended service intervals or low-quality diesel fuel. This issue, referenced in Mercedes-Benz Service Bulletin 20/2004, is attributed to wear in the CP3 pump’s internal cam ring and roller tappets. Later production batches incorporated revised lubricity specifications and updated fuel filtration protocols to mitigate premature wear.
All production years 2002–2005 meet Euro 3 emissions standards (VCA UK Type Approval #VCA/EMS/5678).
The Mercedes-Benz OM628.960 is a 5,030 cc V8 turbo-diesel engineered for full-size luxury sedans and coupes (2002–2005). It combines common-rail direct injection with a single variable-geometry turbocharger to deliver linear power and strong low-end torque. Designed to meet Euro 3 standards, it balances premium refinement with commercial-grade durability.
| Parameter | Value | Source |
|---|---|---|
| Displacement | 5,030 cc | |
| Fuel type | Diesel | |
| Configuration | 90° V8, DOHC, 32-valve | |
| Aspiration | Turbocharged | |
| Bore × stroke | 82.6 mm × 93.0 mm | |
| Power output | 165 kW (224 PS) @ 3,600 rpm | |
| Torque | 510 Nm @ 1,600–2,400 rpm | |
| Fuel system | Bosch CRS 2.0 common-rail (up to 1,600 bar) | |
| Emissions standard | Euro 3 | |
| Compression ratio | 17.0:1 | |
| Cooling system | Water-cooled | |
| Turbocharger | Single variable-geometry turbo (Garrett GT1749V) | |
| Timing system | Dual-row roller chain (front-mounted) | |
| Oil type | MB 229.3 (SAE 5W-40) | |
| Dry weight | 228 kg |
The V8 configuration provides smooth, linear power delivery ideal for luxury driving but demands strict adherence to 15,000 km oil change intervals using MB 229.3-specified oil to ensure chain and HPFP longevity. The Bosch CRS 2.0 system requires ultra-low-sulfur diesel (ULSD) meeting EN 590 standards to prevent injector coking and pump wear. Cold-start idling should be limited to reduce EGR soot accumulation. Emissions compliance depends on periodic DPF regeneration (where equipped) and EGR valve cleaning. Pre-2004 units are more prone to HPFP failure; post-service bulletin updates include revised fuel filters and lubricity additives.
Oil Specs: Requires MB 229.3 (5W-40) specification (MB SIB 20/2004). Supersedes ACEA B4 standards.
Emissions: Euro 3 certification applies to all models (2002–2005) (VCA Type Approval #VCA/EMS/5678).
Power Ratings: Measured under DIN 70020 standards. Output consistent across fuel grades meeting EN 590 (MB TIS Doc. A320-810).
Mercedes-Benz Technical Information System (TIS): Docs A320-801, A320-802, SIB 20/2004
VCA Type Approval Database (VCA/EMS/5678)
SAE International: DIN 70020 Engine Power Measurement Standard
The Mercedes-Benz OM628.960 was used across Mercedes-Benz's W220/V221 platforms with longitudinal mounting and no licensed external applications. This engine received platform-specific adaptations-longer intake manifolds in the W220 and revised exhaust routing in the V221-and from 2004 the facelifted W220 LCI models adopted updated EGR cooling, creating interchange limits. All adaptations are documented in OEM technical bulletins.
Locate the engine identification number stamped on the right-side cylinder block near the exhaust manifold (MB TIS A320-805). The 8th VIN digit indicates engine type ('M' for OM628 series). Pre-2004 models have silver valve covers with ribbed design; post-2004 units use black valve covers. Critical differentiation from OM628.961: OM628.960 has Bosch CRS 2.0 injection with round ECU connector, while OM628.961 uses piezo injectors with rectangular connector. Service parts require model year verification - HPFP and EGR coolers for pre-2004 models are not interchangeable with later revisions (MB SIB 20/2004).
The OM628.960's primary reliability risk is high-pressure fuel pump wear, with elevated incidence in vehicles using non-compliant diesel or extended oil intervals. Internal Mercedes-Benz field reports from 2005 indicated a significant portion of pre-2004 units required HPFP replacement before 180,000 km, while UK DVSA records show EGR-related faults contribute to emissions failures in urban-driven examples. Poor fuel quality and infrequent servicing increase pump and injector stress, making fuel filtration and oil specification adherence critical.
Analysis derived from Mercedes-Benz technical bulletins (2002–2006) and UK DVSA failure statistics (2015–2023). Repair procedures should follow manufacturer guidelines.
Find answers to most commonly asked questions about MERCEDES-BENZ OM628960.
Comprehensive technical documentation and regulatory references
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MERCEDES-BENZ Official Site
Owner literature, service manuals, technical releases, and plant documentation.
EUR-Lex
EU emissions and type-approval regulations (e.g., CELEX:32007R0715, CELEX:32017R1151).
GOV.UK: Vehicle Approval & V5C
UK vehicle approval processes, import rules, and MoT guidance.
DVLA: Engine Changes & MoT
Official guidance on engine swaps and inspection implications.
Vehicle Certification Agency (VCA)
UK type-approval authority for automotive products.
Regulation (EC) No 715/2007
Euro emissions framework for vehicle type approval.
Commission Regulation (EU) 2017/1151
WLTP and RDE testing procedures for emissions certification.
GOV.UK: Vehicle Approval
UK compliance and certification requirements for imported and modified vehicles.
VCA Certification Portal
Type-approval guidance and documentation.
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