In the intake manifold of the 2.2 CDI OM611 Engine there are flaps for the filling channels. OM617 engine 3. Lets start with fuel injectors. Manufacturer Part Number 006.750. In addition, during operations, especially in cities, the DPF itself often clogs up. 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. Save my name, email, and website in this browser for the next time I comment. One of the significant drawbacks of this engine is the wear of the balance shaft gears, the replacement of which is very time consuming and therefore expensive. Issues by Complectations or Trim Levels 3.1. Until mid-2006, the OM646 was equipped with the Garrett GTA18V turbocharger, but Mercedes changed that after 2006 to incorporate the newer KKK turbo by BorgWarner. Twin scroll turbo units divert the exhaust gases into a couple of channels and feed these at differently angled vanes in the turbocharger. The 2.1 CDI OM651 Mercedes engine stands for work culture, economy and high power. Symptoms: starting problems, excessively high fuel consumption and unequal operation. 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. The 2.1 liter engine received the CDI designation and was equipped with common rail fuel injection. The site includes MB Forums, News, Galleries, Publications, Classifieds, Events and much more! Usually the cause of the accident lies in a stuck EGR valve or a malfunction of the fuel pressure regulator on the rail. Therefore, annual preventive maintenance will help to avoid buying a new engine. Adding a supercharger or additional turbo will make large bhp and torque gains, although more difficult to install. We think this one is common sense, but you'll need to match your fuel injector to the type of fuel your car uses as well. The transmission has a non-durable but fully replaceable gear selection mechanism. Fast road cams are one of the most significant mechanical changes, but they must be installed by someone who knows what they're doing and they are not always easy to source but you might find a local firm to regrind a stock camshaft. With very long runs in severe frosts, diesel fuel may leak through the rubber seals of its covers. Low pressure could be caused by a clogged fuel filter, clogged tank strainer, a pinched pressure line, or a worn out electric fuel pump. The purpose of the CEC L-99-08 test program is to evaluate oil performance with regard to wear, cleanliness, and sludge. Read more here! The pulley alternator in + can often fail. 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. Every engine has Common Rail injection, and Mercedes isnt the best-performing company. Equipment failure is caused by mileage and wear. This is not common, however it is known to happen. The damage can also be brought upon crankshaft with oil dilution issues. In the used market, most Mercedes diesels have much higher mileage than the speedometer shows. Best Mercedes AMG Engine: 6.2-Liter V8. JavaScript is disabled. If you continue to use this site we will assume that you are happy with it. Despite the fact that the engine from the Mercedes 2.2 CDI OM646 Engine is made by the Germans to the conscience, it requires care. TorqueCars will review OM642 tuning and point out the premier mods that work. Particle filter accessories arent the most durable either. 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. 125 kW (170 PS; 168 hp) @ 3,800 rpm 400Nm (295lbft) @ 2,000 rpm, 20062009W211 E220 CDI That's the OM646 engine in 150PS / 340Nm guise, prior to the 2006 EVO upgrade to 170PS / 400Nm. This oil is leaking in the tensioner area. Injection pressure up to 2000 bar. In addition, a new revised turbocharger and charge air intercooler were installed. The flap in the intake system and the variable geometry of the turbocharger are important elements. Other modifications were later introduced. keep up with our latest YouTube content and subscribe. Unfortunately, this is far from ideal. . Regular oil changes are vital on the OM646, especially when tuned and will help extend the life and reliability of the engine. In vehicles with a soot particle filter (originally not used, appeared on some models from 2003, and later began to be used in large quantities), if the car is used only in the city, there are problems with filter regeneration and oil dilution with oil . This makes engine repairs much cheaper. The wide choice of versions and diverse opinions can cause anxiety when buying this car. Solved by installing a new pulley. OM601 engine 2.2. Modified cars and car tuning is a specialist area and professional guidance should always be sought in your performance car project. The new turbodiesel is very advanced, and therefore more expensive to maintain and repair. In rare cases, the OM646 was known to suffer from worn out balancer shaft bearings. The Mercedes 2.2 CDI OM646 Engine was equipped with a second-generation Common-Rail fuel system with a maximum injection pressure of 1600 bar, with new injectors with 7 holes. Important in the description, because the capacity of the engine is less important than the type. The crankshaft of the OM646 is forged, so its built to last. Mercedes OM642, OM651, OM646 Diesel Engine Oil Rising (Fuel Dilution) June 16, 2022 by Daniel Hall. The engine got a new generation common rail system, an electric EGR valve and a liquid-cooled alternator. Chassis Cab 4. The OM611 and OM646 engines are 4 cylinders with a displacement of 2.1 liters, although there is also a 2.2 liter variant, but not on this model. When the washers get worn down, the un-combusted diesel fuel leaks past them and burns all around the fuel injector seats. Life On Four is more than just another automotive media outlet. The 2.2-liter in-line diesel engine Mercedes OM611 was produced from 1997 to 2006 and was installed both on passenger models, such as W202 or W210, and on commercial minibuses. The OM646 is a turbocharged inline-four engine produced between 2002 and 2010 by Mercedes-Benz. The engine was offered in five power variants. . Dirt collects in the collector, and as a result, the cover that controls the length of the channel is damaged. Most 2.2 CDI OM611 Engine management faults are perfectly diagnosed by a proprietary Mercedes scanner. 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. When replacing the fuel filter on the 2.2 CDI OM611 Engine, its housing must be filled with diesel fuel manually. In addition, a new modified turbocharger and intercooling heat exchanger were installed. When not working, a power drop occurs. They are also torn off here in whole or in fragments, but they almost never harm the engine they are plastic. Mercedes 2.2 CDI (OM611) Engine Specs, Problems, Reliability, 2.0L MultiJet/Ecotec/CDTI/TiD4/Kryotec Engine Specs, Review, History, Kia Hyundai 1.4 MPi (G4FA) Gamma Engine Specs, Review, History. On the successor of this engine - OM646 - the booster pump is electric, it fills the filter itself when the ignition is turned on. In the most severe cases, the crankshaft cracks. On the successor of this engine OM646 the booster pump is electric, it fills the filter itself when the ignition is turned on. The diesel compression ratio was lowered from 18.0 to 17.5. Hi there, I am Mladen and I am an auto enthusiast. If you continue to use this site we will assume that you are happy with it. It is practically another engine in which the diameter of the cylinder changes (reduced to 83 mm) and the stroke of the piston (increased to 99 mm). A known problem with the 2.1 CDI OM651 diesel engine is a leak in the cooling system. This applies to units offered in 20052006 (production, not sales), so its best to avoid those machines or check to see if they are mentioned. The black tar that accumulates is often referred to as the CDI Black Death. Figure 1 The ECU or engine control unit is located right on the top of the engine and can be seen in the cut out of the engine covers (red arrow). Their strength, however, is simplicity and lack of effort. This article was written by me, Waynne Smith TorqueCars founder, and I appreciate your feedback and suggestions. Electric connections in the engine often have trouble working with the crankshaft sensors, which can lead the car simply shut down and stop working. All engines are equipped with intercoolers. BenzWorld.org forum is one of the largest Mercedes-Benz owner websites offering the most comprehensive collection of Mercedes-Benz information anywhere in the world. You will also have full access to view all petrol gasoline & diesel engine manuals, Applications: The Mercedes-Benz OM 646 is a four-cylinder diesel engine with two overhead camshafts that actuate the 16 valves via hydraulic tappets . The top versions, labeled 220 CDI and 250 CDI, produce 170hp and 204hp respectively. Removing the injector is a difficult task. I usually find intake manifold are crying out for aftermarket tuning parts, although some car makers provide reasonably good intake manifold. If you miss this moment, you can get wear on the belt tensioner. Most tuners we speak with say to be generous with your flow rate on the injectors. Unfortunately, suffers from oil spills and leaks. 3. Such an injection is capable of delivering 1600 bar. 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. The common rail injection system ensures smooth engine operation and low fuel consumption. Be sure to keep up with our latest YouTube content and subscribe. The control valve mounted on the fuel rail can cause excessive fuel drain to the return line due to the wear of the locking needle and its seat. Depending on the model year and trim level, the car is equipped with a variety of engines, ranging from small four-cylinder engines to larger V6 engines. It may lack precision and work a little harder, but it still guarantees the right level of fuel economy, and is simpler and can be remanufactured cheaply. Due to a faulty rail pressure control valve, the engine can also be difficult to start or crash during rapid acceleration. Nozzles break down about 50.000 km. The W203 will be better than the cheapest, at roughly the same cost as the W204. (In some cases, as the factory ECU is locked flashing is not an option, so an aftermarket ECU is the route to take, and many of these will outperform factory ECU's but make sure it has knock protection and that you get it setup properly.). Regular oil + filter changes and frequent motorway runs will help to . Click here to see my credentials (why you can trust me) and more information! Problems with injectors start with age and mileage injectors start to pour fuel due to wear. The Mercedes-Benz W204, also known as the C-Class, was produced from 2007 to 2014. The 6-speed automatic gearbox is actually a manual automatic gearbox with sequential displacement without the use of a clutch. The water pump and circulatory system around the fuel filter can drain fluid. Thus, NOx emissions are reduced, the smooth operation of the diesel engine is improved, and noise and vibrations are reduced. Thermostat to open already at temperatures of 45 degrees. Their pistons are exactly the same. Jan 27, 2017. Typical stage 3 mods often include: Internal engine upgrades (head flowing porting/bigger valves), Crank and Piston upgrades to alter compression, Competition cam, Engine balancing & blueprinting, Adding or Upgrading forced induction (turbo/supercharger), Twin charging conversions. Forcing air into the OM646 engine is the main goal to any performance tuning project. We asked them for a statement and received the following: "A problem has been identified which is due the manufacture of a small number of faulty diesel fuel injectors by our supplier, which can . Tips for N55 Tuning, Tuning Diesels Hence the problems faced by other and subsequent owners. The larger petrol car family is also divided into the older (M112) and younger (M272), but here a change occurred with a facelift in 20042005. Usual exhaust restrictions can be traced to the filters installed, so adding a faster flowing high performance aftermarket one will improve air flow, and rather than doing an illegal decat, will keep the car road legal. The solution is to replace the crankshaft, liners. or 200 CDI . There is also a coupe-style body called the Sportcoupe. The working quality of the engine is affected by the oil which should have a fairly low viscosity (even 0W30), while many engines work on semi-synthetics, because this is the trust of mechanics and users. 271,979 km). Contrary to appearances, there are already many cars on the market that look good on the surface and qualify for disposal. Glow plugs will need changing now and then. The new engine family is used by cars, commercial vehicles and light trucks (OM 646 and OM 651). The shaft can be changed separately. Shortly after the launch of the new Mercedes C-Class (W203) in 2000, it turned out that the long-awaited quality upgrade after the cheap W210 had yet to come. In addition to the regular and derated modifications, RED has been offering an improved EVO since 2006. Excessive Carbon Build-Up. W204 Engine Codes. Since a special stand is required. The third weak point is the variable geometry turbo regulator. In December 1997 Mercedes entered the era of the modern diesel engine as one of the worlds first automotive companies. Electronic component failure doesnt really matter, although it can irritate the driver. The 2.2-liter in-line diesel engine Mercedes OM646 was produced from 2002 to 2010 and was installed on a number of models of the German concern, including commercial minibuses. Work out your MPG Read Also:Mercedes 2.2 CDI (OM611) Engine Specs, Problems, Reliability. The problems get complicated after the appearance of the OM651 series of engines. A number of solutions included in the TwinPulse name are used. 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. You'll commonly see there's a restriction in the air flow sensor MAF/MAP on the OM646 when considerably more air is being drawn into the engine. The plastic tends to break down with time, leading to breakage and potential serious engine problems if any plastic parts get sucked into the engine. Specifications and Modifications. The system is capricious. Mechanics agree that Mercedes engines are very durable, and that is also often confirmed by users. Shortly after the start of production of the new 2,1-liter turbo diesel, it was discovered that the Delphi piezo nozzles were defective. Another weak area is the intake system. Chip tuning Hi Guys, This ones got me pulling my hair out, and there isn't a lot of that :frown 2009 model year 906 633 Sprinter with L4 2.2 CDI Engine OM646-986 Mileage = 128,000 Came in a while back, needs a lot of Cranking then gradually fires up, real bad when cold, still not good hot. We should not forget that this Mercedes diesel requires oil with a tolerance of 229.1. Definition. Shopping for a Mercedes-Benz? The OM611 and OM646 engines are 4 cylinders with a displacement of 2.1 liters, although there is also a 2.2 liter variant, but not on this model. Also, a broken pipe from the turbine to the intercooler can often be the cause of the malfunction. Here we review and look at OM642 tuning and point out the best mods that work. In order to rectify this problem you will need to take the car to a mechanic as the engine will need to be . Each rear wheel is guided by four elements. Particularly the chain tensioner. The Mercedes-Benz OM646 engine is a (2,148 cc) 131.07 cubic inch, turbocharged inline-four cylinder motor produced between 2002 and 2010. Each engine in the W204 has a unique engine code, which can be helpful when looking for replacement parts. 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. Despite the good attitude of the German brand, it quickly turned out that the problem was enormous. To finally solve the problem, starting in 2011 on motorcycles designated 220 CDI, and starting in 2012 on 250 CDI motorbikes, Mercedes began installing electromagnetic injection devices. Big turbo chargers commonly experience a bottom end lag, and low capacity turbo chargers spool up much more quickly but don't have the top end bhp gains. You will find helpful articles and videos on a wide variety of cars - Audi, Mercedes, Toyota, Porsche, Volvo, BMW and much more. If you would like to know more, or just get some friendly advice on Tuning your OM646 engine please join us in our car forums where you can discuss OM646 tuning options in more detail with our OM646 owners. Check our guide on bad fuel injectors to learn more. In terms of issues, there were none that would occur frequently. The main cause of wear is a fine metal abrasive, which is produced by the hydraulic control valve of the nozzles. Bosch electromagnetic devices can be repaired for 80-108 dollars. Modified car insurance One of the most notable features of the Mercedes C200 is its engine. 4- . Advantages Availability. Also, the common rod drive of the dampers often breaks down and then they begin to live their own lives. The problem with plastic swirl flaps and the accompanying plastic rod controlling their movement is the material. The compression ratio of the diesel engine was lowered from 18.0 to 17.5. However, I dont think its worth buying this model for as low as $1500-$2500. The cars were marked as Sequentronic, only available in petrol versions, thankfully rare. "All you need to know about tuning the Mercedes OM646 engine!". 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. We see 4 bar air sensors coping with quite large power gains, whereas the OEM air sensor limited power at a much lower level. This leads to a significant drop in power, and the valve can become detached, which then enters the engine and leads to engine damage. Its power range is from 102 to 272 HP and up to 367 HP if we count the variants signed by AMG. Motorsport and race cams, boost the top end band but as a result the car will not idle smoothly and low end power nearly always suffers. Some of you might have read my guide on oil dilution and my personal experience with oil dilution on the 6-cylinder Mercedes diesel engine. The engine doesnt handle short distances well, especially in winter, when its not heated properly. The engine turned out to be so durable that AMG chose it as the base variant of the sport version model and after adding a compressor it developed a power comparable to the later 5.4l. Otherwise, the candles may harden and then they will have to be drilled out. Tuning . We have a policy of actively enforcing our copyright*. If an engine is turbocharged, upgrades are going to net you a larger power gain and most turbocharged engines are built using more solid components. In 2006, Mercedes-Benz upgraded the OM646 diesel. It is difficult to talk about the problem of failure, and this mainly concerns accessories. These four seals can be re. Wiping on the liner leads to knocking, stopping idling. 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). To keep us running PLEASE Donate here. Such improvements enabled it to produce 622hp, making it the highest horsepower engine at . The 2.1 CDI engine marked OM 651 debuted in 2008. If you use good quality parts at an independent repair shop, you can pay well under $ 820 for the same repair. Gasket Design Multilayer Steel (MLS). ! Where is the number. 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. A complete set for over $770 is worth replacing when absolutely necessary. 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. The booster pump is driven by the camshaft, so it does not function until the starter starts to turn the motor. The new engine was the first common rail Mercedes diesel engine. We love hearing about our website visitors projects, especially the mods done and which work best for you on your car. Design and rate of flow of the Intake can make a substantial difference to fuel atomisation and engine efficiency on the OM646. We have tips on removing carbon build up. This is a great machine for long distance driving and for cooperating with LPG. Ping us if you have anything cool to share on latest cars or on how to make older cars more efficient, or just want to say hi! 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. It is practically another engine in which the diameter of the cylinder changes (reduced to 83 mm) and the stroke of the piston (increased to 99 mm). During 9 years of production, OM651s 2.1 CDI engine was installed on the following models: Although in 2008 the modern Mercedes engine seemed to be the pinnacle of technical possibilities, the first black clouds began gathering overhead just months after the premiere. Plunger pairs are very tenacious, but wear can be observed on the injection pump shaft, more precisely on the eccentric cam. Some sources report that the shortage affected about 300 cars. Euro 4 emission standard compliance (from 2003) on. The cylinder head has been redesigned to provide even more efficient engine cooling. Manufacturer Part Number 61-37200-10. It features a reduced compression ratio of 17.5:1, a new turbocharger, Due to its positioning, it makes it very easy to replace the chain. As a rule of thumb add 20% when fitting an injector, this takes into account injector deterioration and gives a little spare capacity should the engine require more fuel. Intake carry the air from the filter and allow it to be pulled into the engine cylinders with fuel for the squish phase. This can lead to erratic engine behaviour. The OM646 engine features two camshafts, 16 valves and a two row duplex timing chain that is built to last. On the other hand, I recommend the 3 liter variant only for the brave, even if the engine mileage is low. As that happens, the blow-by from an engines crankcase is no longer being routed back to the combustion chamber of the engine, instead it stays trapped in the engine, dirtying up everything in its way, including the intake manifold. Frequent problems of the Mercedes 2.2 CDI OM646 Engine are badass. From the start, the 2.1 CDI OM651 diesel met Euro 5 emission standards. Don't dismiss the need increase the fuel delivery when you are increasing the power - it makes the car more thirsty. Customize a car Mazda SKYACTIV 2.0L and 2.5L engines. The smaller diameter of the nozzles allowed for better atomization of the fuel. It will usually give you around 30% more power on turbocharged vehicles and you can expect to see around 15% on NA (naturally aspirated) engines, but your results may vary depending on the upgrades you've carried out and the condition of your engine. Please help us improve these tips by sending us your feedback in the comments box below. and ceramic glow plugs for improved engine starts. The 2.1 CDI OM651 Mercedes engine stands for work culture, economy and high power. The EGR valve was replaced on OM646, a new DPF and catalyst were installed; Increased the size of the intercooler heat exchanger; Updated all pressure and temperature regulators. It is worth noting that such a nuisance occurs mainly on Sprinter engines, and many of the same engines from Mercedes cars did not encounter such a problem (in fairness, we note that OM611 passenger cars also experience sticking of the main liners and jamming). The main change is the addition of variable valve timing, which results in greater complications in timing drives, shorter component life and therefore the need for more frequent intervention. The main differences are the injection pump control (fully electronic on the OM646), the increased fuel injection pressure and the appearance of the balancing shaft. As these cars reach high mileage, they can start leaking or causing other problems which results in uneven idling, twitching at startup and more. Nozzles can be repaired. Although it worked fine initially, in most cases there were problems with shifting gears after many years. Sports exhausts equal out the flow of gases through the engine. Built with a streamlined idea in mind, so its smaller and loads more. I advise what to choose and what to pay attention to. - Valves in the intake manifold. The more air you can get into an engine, the more fuel it can burn and uprating the induction with a turbocharger upgrade makes massive power gains. Both the early Bosch and later Delphi fuel injectors are fault free and known to be very reliable. New replacement costs at least $ 405. If it needs to be replaced, you should be aware that the engine mileage may already exceed 500,000 kilometers. When you purchase through links on our site, we may earn an affiliate commission, which supports our community. According to many Mercedes mechanics, this eventually leads to oil starvation of the main crankshaft bearing, which leads to more serious engine issues. Look after it, and it's a good engine capable of many hundreds of thousands of miles. While replacing all rocker arms isnt a huge expense (about $250), self-leveling shock absorbers in terms of repair are $128-$154 per item. Thats why it has appeared in the range of German brands for 6 years. Intake and Exhaust - Note that on their own these mods will NOT ADD POWER in most cases, but they can help enhance power after other mods by removing the restriction. In comparison, the new Delphi injector costs $ 450. Why word? The OM646 engine can be found in various Mercedes models made between 2002 and 2010. 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