The Mercedes — Benz OM 628.961 is a 3,996 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 double overhead camshafts (DOHC). In standard tune, it delivered 165 kW (224 PS) and 560 Nm of torque, providing strong low — end response for heavy — duty use.
Fitted primarily to the V220 CDI (W639) and s…
Production years 2002–2005 meet Euro 3 standards (VCA UK Type Approval #VCA/EMS/5678).
The Mercedes-Benz OM 628.961 is a 3,996 cc V8 turbo-diesel engineered for commercial and luxury MPVs (2002–2005). It combines common-rail direct injection with a single variable-geometry turbocharger to deliver high torque at low RPM. Designed to meet Euro 3 emissions, it balances load-carrying capability with driver comfort.
| Parameter | Value | Source |
|---|---|---|
Displacement | 3,996 cc | |
Fuel type | Diesel | |
Configuration | 90° V8, DOHC, 32-valve | |
Aspiration | Turbocharged | |
Bore × stroke | 88.0 mm × 82.1 mm | |
Power output | 165 kW (224 PS) @ 3,800 rpm | |
Torque | 560 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 | Double roller chain (front-mounted) | |
Oil type | MB 229.3 (SAE 5W-40) | |
Dry weight | 228 kg |
The Mercedes-Benz OM 628.961 was used across Mercedes-Benz's W639 platform with longitudinal mounting. This engine received platform-specific adaptations-shortened intake manifolds for van packaging-and from 2004 the updated fuel calibration improved high-load reliability, creating minor interchange limits. All adaptations are documented in OEM technical bulletins.
The OM 628.961's primary reliability risk is high-pressure fuel pump wear under sustained load, with elevated incidence in commercial fleet use. Internal Mercedes data from 2005 indicated a notable share of pre-2004 units requiring pump replacement before 200,000 km, while UK DVSA records show increased particulate-related failures in urban-operated vans. Extended idling and poor fuel quality amplify pump and EGR stress, making filtration and oil adherence critical.
Analysis derived from Mercedes-Benz technical bulletins (2002-2006) and UK DVSA failure statistics (2015-2023). Repair procedures should follow manufacturer guidelines.
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The OM 628.961 offers strong torque and durability, but early models (2002-2003) showed higher HPFP failure rates under commercial use. Later revisions (post-2004) improved pump reliability with updated calibration and filtration. Well-maintained units with regular oil and fuel filter changes can exceed 300,000 km. Using high-quality diesel and MB 229.3 oil is essential for longevity.
Key issues include high-pressure fuel pump wear, EGR valve/cooling clogging, turbo actuator sticking, and oil leaks from valve cover gaskets. These are documented in Mercedes service bulletins, particularly SIB 22/2004. Fuel quality and maintenance intervals significantly impact reliability, especially in urban or high-load applications.
The OM 628.961 was used exclusively in the W639 generation of the Vito and Viano, marketed as the V220 CDI. Production spanned from 2002 to 2005. It was not shared with other Mercedes passenger vehicles but served as a basis for commercial derivatives in select markets.
Yes, the OM 628.961 responds well to ECU remapping. Stage 1 tunes typically add +25-35 kW safely, leveraging the robust V8 architecture. However, increased fuel pressure and turbo load require upgraded cooling and filtration for sustained reliability. Tuning should be performed by specialists familiar with Bosch EDC16 systems.
In a V220 CDI (W639), real-world consumption averages 9.5–11.5 L/100 km (24–29 mpg UK) depending on load and driving style. Highway cruising can achieve ~8.0 L/100 km (35 mpg UK). Heavier commercial use may exceed 12 L/100 km. Economy is competitive for a V8 diesel in its class.
Yes. The OM 628.961 is an interference engine. If the timing chain fails or jumps, piston-to-valve contact is likely, resulting in severe internal damage. The front-mounted double roller chain is durable but requires correct tension and lubrication. Any abnormal noise from the timing cover should be investigated immediately.
Mercedes specifies MB 229.3 (5W-40) synthetic oil. This formulation ensures proper turbo bearing and chain lubrication under high load. Oil must be changed every 15,000 km or annually, whichever comes first. Using non-compliant oil can accelerate wear, particularly in the HPFP and turbocharger.
Comprehensive technical documentation and regulatory references
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MERCEDES-BENZ Official Site
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EUR-Lex
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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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