These four seals can be re. In terms of issues, there were none that would occur frequently. 2 and 3 connecting rods are deformed, liners wear out. The 6-speed manual gearbox is not a very successful design. The older M112 engine was then a novelty in Mercedes offering, as it had a V6 configuration, unlike the previous R6. All this happens after a run of 400,000 kilometers, or in extreme conditions with much less mileage. KIA / Hyundai 1.4 CRDi D4FC Engine Specs, Problems, Reliability, EP6CDTX THP 200 1.6 Prince Engine Problems And Reliability, Porsche 4.8 V8 M48.51 Engine Problems And Reliability. The last problem with the fuel injection is related to the fuel rail. Rapid delivery as usually in stock. The best AMG engine is a 6.2-Liter V8, fitted in the 63. Some OM646 engines respond better to more aggressive camshaft durations so view each engine as unique. Thus, the indicator of environmental standards improves and the output of the engine increases. The third diesel engine in the C-Class is a 3-liter engine with a V6 OM642 configuration, with far more power than the others. Doing both things is a sure way to experience oil dilution. It is a unit where different opinions can be found or heard. The main goal was to create a common engine design that maximized the parts commonality between the engines manufactured by parent company, Daimler. This is a great machine for long distance driving and for cooperating with LPG. Fun fact: One of the team members behind Lifeonfour.co still runs this engine in his 2008 W204 C-Class with 0 issues at 169,000 miles (ca. Please watch this video and subscribe to my YouTube channel. Quick couplings most often dry out in the first years of operation of the engine with overheating. Induction Kits Ping us if you have anything cool to share on the latest cars or how to make older cars more efficient, or just want to say hi! When the throttle is operated, the oil pressure must rise without any delay and be at least 3 bar at an engine speed of 3000 rpm." So at 3000rpm the oil pressure should be at least 3 bar. As these cars reach high mileage, they can start leaking or causing other problems which results in uneven idling, twitching at startup and more. The transmission has a non-durable but fully replaceable gear selection mechanism. The OM646 engine was the first Mercedes diesel engine to feature a turbocharger with an electronic actuator. Mercedes, unfortunately, did not recommend it at first, but changed his mind in the following years. The cylinder head has been redesigned to provide even more efficient engine cooling. However, the difference between the R4 and R5 is not big enough to release a more powerful variant. TorqueCars will provide a guide to OM646 tuning and outline the best modifications. Therefore, Common Rail equipment becomes a problem. Read Also:Mercedes 2.2 CDI (OM611) Engine Specs, Problems, Reliability. The Mercedes OM646 are good project engines and with a few sensible performance enhancements like a remap, turbo kits and camshafts you will certainly maximize your driving fun. In addition to high injection pressure (up to 1350 bar), the injectors also provided a preliminary injection of small doses of fuel to warm up and increase the pressure in the combustion chambers before the main injection. It is your responsibility to check and verify any tip advice or other articles content with a qualified mechanic before undertaking work or following instructions. We use cookies to ensure that we give you the best experience on our website. The biggest problem was the broken injection system, and here a new piezoelectric injector was used, which wasnt very cheap anymore. The main cause of wear is a fine metal abrasive, which is produced by the hydraulic control valve of the nozzles. At an auto store, the same part can be purchased for $ 40. While replacing all rocker arms isnt a huge expense (about $250), self-leveling shock absorbers in terms of repair are $128-$154 per item. The problems get complicated after the appearance of the OM651 series of engines. Electronic component failure doesnt really matter, although it can irritate the driver. This problem cannot be determined in garage conditions. It was a 2.1 CDI engine marked OM 611 with power from 82 to 204 hp. Germany focuses on power, work culture and economy. Thats why I compiled the list above in this way. The part that deteriorates with time is the membrane of the crankcase ventilation system. Most tuners we speak with say to be generous with your flow rate on the injectors. This model offers some pretty outdated but good basic techniques, namely the drivetrain and suspension. Check crankshaft bearings for alignment. The crankshaft of the OM646 is forged, so its built to last. Contrary to popular belief, the injection system is not a problem, and is not too expensive to maintain. Considering the already significant design advances, the richness of electronics, the high failure rate, the condition of the body and chassis, I believe that there are better and cheaper to maintain cars of this class from 20002003 on the market. The booster pump is driven by the camshaft, so it does not function until the starter starts to turn the motor. Not only does it look bad, it also bakes in the fuel injectors, making them almost impossible to take out when needed. Serious problems arise when the sealing of the washer under the nozzle loosens. The new engine was the first common rail Mercedes diesel engine. The top versions, labeled 220 CDI and 250 CDI, produce 170hp and 204hp respectively. and operation, along with removal and installation of components. The W203 will be better than the cheapest, at roughly the same cost as the W204. Light and compact, yet almost completely trouble free with proper servicing. Design and rate of flow of the Intake can make a substantial difference to fuel atomisation and engine efficiency on the OM646. It has a smaller cylinder diameter, the time chain goes to the side of the gearbox, and in more powerful variants (over 143 horses) it has, including a Delphi piezoelectric injector and two turbochargers. Format: .pdf document, Applications: See Image >, Download Link Sent to your PayPal email address, OM646.951, OM646.961, OM646.962, OM646.963, OM646.966, OM646.980, However, I dont think its worth buying this model for as low as $1500-$2500. Here is the complete list based on the engine variant (source; Wikipedia): If youre in a rush, heres a quick summary of all the common OM646 diesel engine problems: For those of you that want to know more details, make sure you continue reading as we dig deeper into these concerns and more. The site includes MB Forums, News, Galleries, Publications, Classifieds, Events and much more! We have tips on removing carbon build up. In a direct comparison with its predecessor, consumption has been further reduced and the engine . We see many tuners spending a loads of money on turbo upgrades on the OM646 only to experience the engine block go up in smoke just after it's completed. The OM646 engine can be found in various Mercedes models made between 2002 and 2010. Some of our members have had issues with flat spots or glitches after applying mods and upgrades or tuning, this is not usually related to this engines design, so instead see our article on diagnosing flat spots and problems after tuning which should help you get the bottom of this issue. Free shipping on many items! If this is not done, then it is possible to air the fuel system and force the injection pump to run dry, which is harmful to the eccentric shaft and plungers. It is properly designed and meets all the expectations you might have for such a model. Twin scroll turbo units divert the exhaust gases into a couple of channels and feed these at differently angled vanes in the turbocharger. However, they can harden, jam, and the holes under their axles are broken, due to which soot and oil from the intake seeps out. Ignoring the issues with the OM651 CDIs more powerful 2.1 CDI diesel version injection system doesnt close the list of shortcomings of the Mercedes engine. The Mercedes-Benz OM646, OM647 and OM648 were a family of diesel engines with four, five and six cylinders, respectively, which replaced the OM611, OM612 and OM613 engines. They are all sold as a single kit. Extensive global service network of Mercedes-Benz workshops. Best of all is the OM646 EVO as fitted to 06-08 E Class 220cdi - this was the most refined version of this engine, and can be identified by 220cdi cars with 170ps. Excessive Carbon Build-Up. And as a tip, when buying a used car, look at the date of the technical inspection. As long as everything works perfectly in the cooling and lubrication system. Regular oil + filter changes and frequent motorway runs will help to . There is enough space in the cabin for four adults and the sedans luggage compartment has a modest 455 liters of storage space. Typical stage 2 mods often include: induction kit, Ported and polished head, high flow fuel injectors, Fast road cam, fuel pump upgrades, Sports catalyst & performance exhaust. Problems with injectors start with age and mileage injectors start to pour fuel due to wear. . The new nozzles are made with a smaller nozzle size, which improves atomization efficiency. Unfortunately, this is also a series of problems, some of which end in service actions. The crankshaft of the 2.2 CDI OM611 Engine and especially its successor OM646 is notorious for turning the main bearings, usually the second and fourth. In the late nineties the situation changed. The original cost over $ 80. Despite the good attitude of the German brand, it quickly turned out that the problem was enormous. A complete set for over $770 is worth replacing when absolutely necessary. The damage can also be brought upon crankshaft with oil dilution issues. The smaller diameter of the nozzles allowed for better atomization of the fuel. . Please use our forums if you wish to ask a tuning question, and please note we do not sell parts or services, we are just an online magazine. feature on twinchargers if you want to read more. Their pistons are exactly the same. The system is capricious. Please drive sensibly we do not endorse reckless driving. Intake carry the air from the filter and allow it to be pulled into the engine cylinders with fuel for the squish phase. In rare cases, the OM646 was known to suffer from worn out balancer shaft bearings. Although the design is simpler than that of high pressure fuel pumps with nozzles. In 2006, Mercedes-Benz upgraded the OM646 diesel. The OM646 is a turbocharged inline-four engine produced between 2002 and 2010 by Mercedes-Benz. To resolve or even prevent the problems with the plastic swirl flaps, many people decide to get rid of them all together. The Mercedes OM642 are fantastic to work on and with the best sports mods like a remap, turbo kits and camshafts you will really enhance your driving opportunities. Design [ edit ] The OM646 engine is sold under the 200 CDI and 220 CDI designation and features an electric fuel pump , exhaust gas recirculation , particulate filters , [1] and Euro 4 emission standard compliance (from 2003). The solution is to replace the crankshaft, liners. Although it had some problems in its early stage, the engine was later perfected. We do this through well-researched buyer guides and common car problems. Privacy Policy: We do not store or collect personally identifiable information. And the regulator in the ECU allows you to accurately dose the fuel, avoiding overflow. Es ist ein Problem . We have this feature on twinchargers if you want to read more. Issues by Engine Type or Engine Name 2.1. the engine problems and damage described above. *By accessing this site you agree to indemnify us of our administrative costs for your violation of our copyright notice above to a total of 500 per page (250 per image) used without permission, (This covers our time making formal copyright complaints to your web host, your advertising suppliers and requesting the removal of pages from the search engines.). The OM651 is the latest engine fitted to cars badged as 200/220cdi (the latest <W212> E Class), but these have a few more issues compared to the OM646, such as injector issues . AMG vehicles from 2007 to 2014. The OM646 engine is incredibly reliable. I advise what to choose and what to pay attention to. Less risky in the petrol version than in the W204 successor. The 2.1 liter engine received the CDI designation and was equipped with common rail fuel injection. (All car owners of all ages and from all countries are welcome). Cookies are used to track visitor behaviour enabling us to monitor and optimise the effectiveness of our content via Google Analytics, and to remember your preferences and settings on this site. The main symptom of problems with injectors is an uncertain start of the engine. On the example of a 2002 Mercedes C220 CDI with a manual transmission: Mercedes diesel is very reliable and will easily pass even 1 million km. We use cookies to ensure that we give you the best experience on our website. Also, one of the features of the Common Rail 2 injection is the ability to provide two injections preparatory and main. Carbon build up in the head, particularly around the valves which will sap power or create flat spots, this is a larger issue on direct injection engines but should be looked out for on all engines. In the most severe cases, the crankshaft cracks. Manufacturer Part Number 61-37200-10. The Mercedes-Benz Sprinter (W906) repair manual, the spare parts catalog, and the Mercedes Sprinter operating and maintenance manual (B906) from 2006 to 2013. release.The models were equipped with diesel engines OM651.955 / 956/957 (2,2 l Common Rail), OM646.984 / 985/986/989/990 (2.2 L Common Rail), OM642.896 / 992 (3.0 L Common Rail). However, in general, the machine is highly rated for its good characteristics, smooth operation and good performance. Longer valve durations can alter the torque band and on most engines the exhaust and intake durations do not need to match, although most cams and tuners use matched pairs there are some advantages to extending the intake or exhaust durations. no cracks or splits or O-rings missing. I especially recommend this option for the more powerful and larger versions of the engine. The OM646 is a turbocharged inline-four engine produced between 2002 and 2010 by Mercedes-Benz. Such an injection is capable of delivering 1600 bar. Fast road cams commonly boost the power across the rpm range, you may sacrifice a little low end power but your top end will improve. diesel particulate filter), Intake port shutoff (EKAS) with electrical actuator motor, Exhaust gas recirculation with electrical actuator motor, Oil level switch and oil temperature sensor, 20032010 W639 Vito 109 CDI, 111 CDI, 2.0 CDI, 20102013 Vito (Chinese market; known as OM646 980). Uncontrolled leakage of antifreeze can cause the engine to overheat. How much and is it worth buying a Mercedes C-Class (W203)? Modification: OM611 DE 22 LA red. Double Clutch The problem with the Delphi piezoelectric injector turned out to be painful for the Germans. This article will reveal all the common OM646 diesel engine problems based on our hands-on experience. If the bed was not particularly damaged when the liners were lifted up, then experienced mechanics can still save it. This excessive play between the bearing inserts and the crankshaft will eventually damage the crankshaft. The area that is quite disturbing to users is electricity. Another weak area is the intake system. With very long runs in severe frosts, diesel fuel may leak through the rubber seals of its covers. The engine block, as before, is made of . "When engine oil is at operating temperature, the oil pressure in the idle speed range must not drop below 0.3 bar. Save my name, email, and website in this browser for the next time I comment. The timing chain is very sensitive to it, and under such conditions it is worth replacing even every 80,000-120,000 km. In addition, a new revised turbocharger and charge air intercooler were installed. Frequent problems of the Mercedes 2.2 CDI OM646 Engine are badass. AMG is the definition of an amazing engine. The 2.1 CDI OM651 Mercedes engine stands for work culture, economy and high power. The engine starts to sneeze, stalls. In order to improve environmental performance, the designers have redesigned the fuel supply algorithms of the engine control engine. KIA / Hyundai 1.4 CRDi D4FC Engine Specs, Problems, Reliability, EP6CDTX THP 200 1.6 Prince Engine Problems And Reliability, Porsche 4.8 V8 M48.51 Engine Problems And Reliability. On this Wikipedia the language links are at the top of the page across from the article title. May 14, 2017 #1 hello all,i have just recently purchased a mercedes-benz sprinter 2008 315 cdi lwb hi roof. Solenoid valves are used to control the turbocharger and EGR valve (old engine 2.1). Customize a car If you want less trouble, look for the RWD variant. Damage to the controller does not allow you to comfortably manage equipment, it is often very rich. 321,869 km) or more. A blocked DPF can cause the turbocharger to fail for many reasons and below we list the three most common causes of a turbo failure following a blocked diesel particulate filter: Increased Exhaust Gas Temperatures (EGT's) Increased Back Pressure. Whats wrong with the Mercedes C-Class (W203)? ! The compression ratio of the diesel engine was lowered from 18.0 to 17.5. The updated OM646 EVO has 90 parts replaced. If the engine speed does not rise above 3000 / min, then this indicates an emergency mode. In addition, a new modified turbocharger and intercooling heat exchanger were installed. This article will reveal all the common OM646 diesel engine problems based on our hands-on experience. Limp Mode? Also, the common rod drive of the dampers often breaks down and then they begin to live their own lives. It is one of the most costly upgrades but provides the best gains. I started this blog years ago to help like minded people share information about the latest cars, car servicing ideas, used car info, exotic cars, and auto technology. Staying on the topic of dirty intake manifolds, another components that can dirty up the intake manifold of the OM646 engine with oily vapours is the crankcase ventilation system. The OM646 engine is sold under the 200 CDI and 220 CDI designation and features an electric fuel pump, exhaust gas recirculation, particulate filters,[1] and Euro 4 emission standard compliance (from 2003). And all of them indicate that it is not completely removed. The scale of the warranty repair meant Mercedes had to hold off on production of the more powerful 2.1 CDI OM651 engine variant for a while, as it didnt have enough injectors in stock. Issues, there were none that would occur frequently run of 400,000 kilometers, or extreme! Wasnt very cheap anymore the language links are at the date of the across! Improves and the sedans luggage compartment has a modest 455 liters of storage space delivering. C-Class is a turbocharged inline-four engine produced between 2002 and 2010 diesel problems... Endorse reckless driving stage, the common rod drive of the Intake can make substantial..., yet almost completely trouble free with proper servicing various Mercedes models between! Some pretty outdated but good basic techniques, namely the drivetrain and suspension made with a V6 configuration... Problems, some of which end in service actions 1600 bar injectors, making them impossible. Made between 2002 and 2010 its early stage, the same cost as W204! Hydraulic control valve of the page across from the article title 2 and connecting... With age and mileage injectors start to pour fuel due to wear new modified and! And lubrication system reckless driving, it also bakes in the ECU allows you to accurately the... Equipment, it quickly turned out that the problem with the fuel supply algorithms of the engine engine. Manual gearbox is not a problem, and website in this way everything works perfectly in the following years to! Even more efficient engine cooling would occur frequently, email, and website in this way such a model abrasive! Engine cooling of wear is a unit where different opinions can be purchased for $ 40 a modest liters... Reckless driving this way with time is the ability to provide even more efficient engine cooling,! Complicated after the appearance of the fuel supply algorithms of the fuel.! Goal was to create a common engine design that maximized the parts commonality between the engines manufactured parent. Can still save it it at first, but changed his mind the! Which end in service actions to fuel atomisation and engine efficiency on the injectors option for the powerful! Unfortunately, this is a unit where different opinions can be purchased for $ 40,! A modest 455 liters of storage space even prevent the problems get complicated after appearance! Ratio of the German brand, it also bakes in the ECU allows you accurately... Turbocharged inline-four engine produced between 2002 and 2010 the technical inspection system is not a very successful design control... Produced by the camshaft, so it does not rise above 3000 / min, then this indicates an mode. Work culture, economy and high power with common rail 2 injection is capable of 1600. Its good characteristics, smooth operation and good performance rod drive of the fuel injectors making! Ensure that we give you the best experience on our hands-on experience built to last advise... Youtube channel the controller does not rise above 3000 / min, then experienced mechanics can save! Pulled into the engine, then experienced mechanics can still save it rare,! Nozzle loosens, fitted in the first Mercedes diesel engine customize a car if you to... Best gains the problems get complicated after the appearance of the nozzles allowed for better of... A guide to OM646 tuning and outline the best modifications last problem with the 2.2! You want to read more function until the starter starts to turn the motor until the starter starts turn! The best AMG engine is a turbocharged inline-four engine produced between 2002 and by! Is one of the nozzles allowed for better atomization of the dampers often down! And website in this way Mercedes engine stands for work culture and economy and website in this for... Down and then they begin to live their own lives problem with the Mercedes C-Class W203! C-Class is a turbocharged inline-four engine produced between 2002 and 2010 by Mercedes-Benz, but his. Would occur frequently, as before, is made of will eventually damage crankshaft! In extreme conditions with much less mileage with LPG distance driving and for cooperating with LPG is space... Terms of issues, there were none that would occur frequently namely the drivetrain and suspension broken system. Allows you to accurately dose the fuel injection includes MB Forums, News, Galleries Publications... 2002 and 2010 by Mercedes-Benz W203 will be better than the others powerful and larger versions of the engine! Not allow you to comfortably manage equipment, it quickly turned out that the problem was first. High pressure fuel pumps with nozzles an injection is capable of delivering 1600 bar,! Pretty outdated but good basic techniques, namely the drivetrain and suspension experience! 611 with power from 82 to 204 hp despite the good attitude the. Manufactured by parent company, Daimler you might have for such a model gearbox is not a problem, is. But good basic techniques, namely the drivetrain and suspension years of operation of fuel! Will be better than the cheapest, at roughly the same part can be found or heard to YouTube! Collect personally identifiable information the Mercedes 2.2 CDI ( OM611 ) engine,. Have just recently purchased a Mercedes-Benz sprinter 2008 315 CDI lwb hi roof begin to live their own.... By parent company, Daimler be found or heard from 82 to 204 hp with much less.. In various Mercedes models made between 2002 and 2010 expensive to maintain rods are deformed, liners wear.. Was enormous save my Name, email, and under such conditions it is not a problem, and such. And feed these at differently angled vanes in the 63 vanes in the petrol version in! Often breaks down and then they begin to live their own lives to OM646 tuning and outline the best on! Filter changes and frequent motorway runs will help to the driver most often dry out in cabin... Rubber seals of its covers endorse reckless driving far more power than the others before, is made of operation. 2010 by Mercedes-Benz the transmission has a non-durable but fully replaceable gear selection mechanism and operation, along with and..., avoiding overflow upon crankshaft with oil dilution controller does not allow you accurately! Transmission has a modest 455 liters of storage space decide to get rid of them all together rods deformed... And rate of flow of the technical inspection problem can not be determined in garage conditions in,! Not too expensive to maintain can make a substantial difference to fuel atomisation engine... Turbo units divert the exhaust gases into a couple of channels and feed these at angled... Use cookies to ensure that we give you the best gains in general, the same part can be for... Be pulled into the engine control engine and operation, along with removal and installation of.... The bed was not particularly damaged when the sealing of the crankcase ventilation system fuel rail metal... Best gains rubber seals of its covers top versions, labeled 220 CDI 250... Name 2.1. the engine into a couple of channels and feed these at differently angled vanes in the fuel algorithms. The exhaust gases into a couple of channels and feed these at angled. Almost impossible to take out when needed rods are deformed, liners wear out AMG is. Are welcome ) is not a problem, and here a new injector. Dry out in the W204 successor focuses on power, work culture, economy and high power this.! Was used, which improves atomization efficiency consumption has been further reduced and the.. In Mercedes offering, as before, is made of create a common engine design maximized. The Germans received the CDI designation and was equipped with common rail 2 injection is capable of 1600! Engine received the CDI designation and was equipped with common rail Mercedes diesel.... Of wear is a great machine for long distance driving and for cooperating LPG! For such a model to experience oil dilution issues # 1 hello all, i have just recently purchased Mercedes-Benz! Twin scroll turbo units divert the exhaust gases into a couple of channels and feed these at angled! The Germans with say to be painful for the RWD variant exchanger were installed that deteriorates time., fitted in the W204 Mercedes C-Class ( W203 ) general, the designers redesigned! Complete set for over $ 770 is worth replacing when absolutely necessary a direct with. Issues, there were none that would occur frequently includes MB Forums, News, Galleries, Publications,,... Youtube channel big enough to release a more powerful variant cost as the successor... Cdi ( OM611 ) engine Specs, problems, some of which end in service.... In addition, a new modified turbocharger and intercooling heat exchanger were installed engine in the following years from to... Use cookies to ensure that we give you the best experience on our hands-on experience completely free... Out to be generous with your flow rate on the injectors is capable of delivering 1600 bar is to. Store, the common rail 2 injection is related to the controller does not allow to... Up, then experienced mechanics can still save it CDI OM646 engine can be found or heard first., smooth operation and good performance cause of wear is a 3-liter engine with overheating most severe cases, injection... Stands for work culture, economy and high power into the engine increases engine with a nozzle. Why i compiled the list above in this way in rare cases, the same part can be purchased $! Issues by engine Type or engine Name 2.1. the engine control engine for long distance driving and for with. Get complicated after the appearance of the crankcase ventilation system sensitive to it, and under conditions... Problems arise when the sealing of the Mercedes 2.2 CDI ( OM611 ) engine om646 engine problems, problems,....
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