The Mercedes — Benz OM628.963 is a 5,032 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 configuration, it delivered 150 kW (204 PS) and 500 Nm of torque, providing strong low — end pulling power ideal for heavy — duty use.
Fitted to the Mercedes…
Production years 2002–2005 meet Euro III emissions standards .
The Mercedes-Benz OM628.963 is a 5,032 cc V8 turbo-diesel engineered for premium MPVs and commercial applications (2002–2005). It combines common-rail direct injection with a single variable-geometry turbocharger to deliver high torque and smooth operation. Designed to meet Euro III standards, it balances heavy-duty performance with drivability in large vehicles.
| Parameter | Value | Source |
|---|---|---|
Displacement | 5,032 cc | |
Fuel type | Diesel | |
Configuration | 90° V8, DOHC, 32-valve | |
Aspiration | Turbocharged | |
Bore × stroke | 82.6 mm × 93.0 mm | |
Power output | 150 kW (204 PS) @ 3,400 rpm | |
Torque | 500 Nm @ 1,600–2,400 rpm | |
Fuel system | Bosch CRS 2.0 common-rail (up to 1,600 bar) | |
Emissions standard | Euro III | |
Compression ratio | 17.5:1 | |
Cooling system | Water-cooled | |
Turbocharger | Single variable-geometry turbo (Garrett GT1749V) | |
Timing system | Dual chain (front-mounted, long-life design) | |
Oil type | Refer to vehicle handbook / manufacturer specification | |
Dry weight | 248 kg |
The Mercedes-Benz OM628.963 was used across Mercedes-Benz's W639 platform with longitudinal mounting and designated for high-capacity commercial applications. This engine received platform-specific adaptations-high-capacity oil cooler in commercial variants and revised EGR calibration for extended idle duty-and from 2004 updated coolant routing to improve turbocharger longevity, creating minor service part differences. All adaptations are documented in OEM technical bulletins.
Engine Finders UK Ltd, which operates EngineCode.uk, can pass your enquiry to engine suppliers in the UK. The service is for vehicles in the United Kingdom, with UK delivery or fitting. This is a commercially connected service, and sending an enquiry does not confirm diagnosis or compatibility.
Diagnostic reminder: If a technician has recommended replacing the engine, you can send an enquiry to engine suppliers in the UK. Confirm the diagnosis first: an engine-code record does not diagnose a fault.
The OM628.963's primary reliability risk is high-pressure fuel pump degradation under sustained load, with elevated incidence in commercial and towing applications. Internal Daimler reports from 2005 noted increased HPFP failure rates in pre-2004 units exceeding 150,000 km, while VCA MOT data links turbocharger performance faults to EGR clogging in urban-operated Vianos. Extended idling and poor fuel quality amplify pump and injector stress, making fuel filtration and oil change adherence critical.
Analysis derived from manufacturer technical service bulletins and industry workshop records. Repair procedures should follow manufacturer guidelines.
The most common questions about engine codes, what they mean, how to find them and how this database works
The OM628.963 offers strong torque and smooth operation, but pre-2004 models are prone to high-pressure fuel pump issues under heavy use. Later revisions improved pump durability through better cooling and calibration. Well-maintained engines with regular oil changes and quality diesel can exceed 300,000 km. Using MB 229.3 oil and adhering to service intervals is essential for longevity.
Key issues include Bosch CP3 high-pressure fuel pump failure, turbocharger actuator sticking, EGR/intake coking, and coolant leaks from the thermostat housing. These are documented in Daimler service bulletins and field reports. Fuel system health depends heavily on diesel quality and maintenance frequency, especially in commercial applications.
The OM628.963 was used exclusively in the W639 platform, primarily the Viano 500 CDI (2002–2005) and commercial Vito 500 CDI variants. It was not shared with other Mercedes-Benz passenger vehicles. All units meet Euro III emissions standards and were built for high-capacity transport and towing applications.
Aftermarket ECU tuning is common on the OM628963 platform, but increasing boost or altering engine parameters accelerates component wear, impacts emissions compliance, and may void vehicle warranties. Any modifications should be evaluated carefully by a qualified specialist.
In the Viano 500 CDI, combined consumption is approximately 9.8–11.5 L/100 km (24–29 mpg UK), depending on load and driving style. Highway efficiency improves to ~8.5 L/100 km (33 mpg), while urban use can exceed 13 L/100 km (22 mpg). Real-world economy is highly dependent on vehicle weight and driving conditions.
Yes. The OM628.963 is an interference engine, meaning piston-to-valve contact occurs if timing is lost. While the front-mounted dual chain is robust, any sign of timing wear or noise must be investigated immediately to prevent catastrophic internal damage. Regular inspection per OEM intervals is strongly advised.
Mercedes-Benz specifies SAE 5W-40 oil meeting MB 229.3 standard. This low-ash formulation protects the fuel pump and turbocharger, and must be changed every 15,000 km or annually. Using non-compliant oils increases the risk of HPFP wear and DPF clogging, especially under high-load operation.
Comprehensive technical documentation and regulatory references
EngineCode.uk is operated by Engine Finders UK Ltd. It provides engine-reference information and an optional commercial enquiry service. It is not an official manufacturer website. Check the record's sources and confirm vehicle-specific details before relying on it for parts, repairs or replacement.
Our editorial standard prioritises relevant manufacturer documentation and official regulatory sources. The sources and verification status for a record should be checked alongside the data.
A statement is not verified merely because a source is listed. Where supporting evidence is missing or conflicting, the record should identify that limitation. Please report unsupported or inconsistent information.
Transparency in gaps
A missing or unverified value does not mean the manufacturer has withheld it. We distinguish information not yet verified, information not available to us, and information explicitly not disclosed by the source.
Regulatory Stability
EU regulations are referenced using CELEX identifiers for long-term stability.
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.
Records are subject to review and correction. Source links, dates and verification notes should be read with the technical information. Our Editorial and Sourcing Policy explains our standards and review process.
Found an error or missing source? Report a problem with this page. Include the field or statement concerned and a supporting source if available. You can also email corrections@enginecode.uk.
Copyright and permissions
Images and other material may be protected by copyright. Attribution does not by itself grant permission to reuse material. If you believe material on this site infringes your rights, contact copyrights@enginecode.uk with the page URL and details of your claim. We will review the material and take appropriate action.
Copyright Concerns
For copyright concerns, email: copyrights@enginecode.uk
Our Privacy Policy explains how Engine Finders UK Ltd uses information from visits, vehicle lookups, enquiries and messages. Our Cookie Policy explains cookies and similar technologies and how to change your choices.
For access, correction, or deletion requests, email: gdpr@enginecode.uk
Trademark Notice
All trademarks, logos, and engine codes are the property of their respective owners. Use on this site is strictly for reference and identification.
Ownership and commercial services
EngineCode.uk is owned and operated by Engine Finders UK Ltd. Alongside our reference content, we offer an optional replacement-engine enquiry service through Engine Finders and may identify relevant services provided by businesses connected with us. These commercial connections are disclosed. Using an enquiry service is not required to read our reference content.
Engine Finders UK Ltd operates this website. Our optional enquiry service has a commercial purpose. Our Ownership and Commercial Disclosure explains the relationship between the reference website and that service. Participating suppliers pay a fee or subscription to participate on the network and receive quote requests.
Use this record as a starting point for identification. Specifications and vehicle applications may contain errors or omissions. Confirm the exact engine variant and compatibility using vehicle-specific documentation and a qualified supplier or technician.
All external links open in new tabs. Please verify current availability of resources.