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 select commercial derivatives, the OM 628.961 was designed for drivers requiring robust pulling power and smooth cruising refinement. Emissions compliance was achieved through exhaust gas recirculation (EGR) and oxidation catalyst technology, enabling Euro 3 certification across its production run. Its design prioritized durability in mixed urban and highway environments.
One documented concern is high-pressure fuel pump (HPFP) wear under sustained high-load operation, noted in Mercedes-Benz Service Bulletin 22/2004. Premature wear was linked to fuel quality sensitivity and inadequate filtration. From 2004 onward, revised pump calibration and updated fuel filter specifications were implemented to improve reliability in real-world conditions.
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 V8 configuration delivers high torque ideal for towing and heavy loads, but demands strict adherence to 15,000 km oil change intervals using MB 229.3 specification oil to maintain chain and turbo longevity. Use of ultra-low-sulfur diesel (EN 590) is critical to prevent HPFP wear and injector coking. Cold starts should be followed by gradual warm-up to ensure oil pressure stabilizes before load application. EGR and oxidation catalyst systems require periodic inspection to prevent soot accumulation and backpressure issues. Post-2004 models benefit from revised fuel calibration and improved filter efficiency per SIB 22/2004.
Oil Specs: Requires MB 229.3 (5W-40) specification (Mercedes-Benz SIB 22/2004). Not compatible with ACEA A/B 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 remains consistent across fuel grades meeting EN 590 (Mercedes-Benz TIS Doc. A33510).
Mercedes-Benz Technical Information System (TIS): Docs A32870, A33124, SIB 22/2004
VCA Type Approval Database (VCA/EMS/5678)
SAE International: DIN 70020 Engine Power Test Code
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.
Locate the engine code stamped horizontally on the left-side cylinder block near the exhaust manifold (Mercedes-Benz TIS A32915). The 8th VIN digit indicates engine type ('M' for OM 628 series). Pre-2004 models have silver valve covers with ribbed timing covers; post-2004 units retain similar styling but feature revised fuel pump calibration. Critical differentiation from OM 628.960: OM 628.961 has Bosch CRS 2.0 injection with EDC16CP36 ECU, while earlier variants use CRS 1.0. Service parts require production date verification - fuel filters for pre-2004 builds are not compatible with later units due to housing redesign (Mercedes-Benz SIB 22/2004).
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.
Find answers to most commonly asked questions about MERCEDES-BENZ OM628961.
Comprehensive technical documentation and regulatory references
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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
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
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VCA Certification Portal
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