Mercedes-Benz E 220 D
Pre-chamber four-cylinder, successor to the OM601. Economical and reliable but outdated in terms of power. Check glow plugs regularly.
Underpowered
Just 70 kW — barely enough to keep up with traffic.
Engine Weaknesses 6
The electronically controlled Lucas EPIC distributor injection pump is inherently fault-prone. Internal leaks and defective solenoid valves cause limp mode or complete failure. Replacement with a Bosch pump is recommended.
Symptoms: EDC warning light, power drop to ~3,000 rpm (limp mode), sporadic starting difficulties, engine runs on after switching off
The aluminium cylinder head is more prone to trapping glow plugs than cast iron heads. When changing, the plug can snap off, forcing expensive head removal.
Symptoms: Cold start problems, rough running below 5 degrees C, glow plug warning light flashing irregularly
The OM604 has an aluminium cylinder head that warps when overheated. Head gasket failures documented from approximately 114,000 km, with normal use usually significantly later.
Symptoms: Coolant loss without visible external leak, white smoke from exhaust, oil film in coolant, engine overheats
The hydraulic chain tensioner loses oil pressure at high mileage, causing cold-start rattling. In the worst case the chain jumps.
Symptoms: Rattling at cold start for 1–3 seconds; with advanced wear, continuous rattling and engine speed fluctuations
The thin 6mm intake valve stem on the OM604 elongates beyond the compensation range of the original hydraulic tappets. BGA repair tappets (1 mm shorter) allow a cost-effective repair.
Symptoms: Poor cold-start behaviour, engine barely starts in sub-zero temperatures, rough running after starting that normalises only after warm-up
Engine mounts on the OM604 in the W202 tend to wear from approximately 150,000–200,000 km. Aftermarket mounts (Corteco) at €24–€50 per unit. Complete set with fitting approximately €460.
Symptoms: Vibrations at idle, judder during gear changes, droning at approximately 80 km/h, noticeable vibrations at gear lever
Vehicle Weaknesses 6
Bacterial contamination in the electrophoretic coating bath compromised paint adhesion. Rust appears on doors, roof, boot lid and trim strips. Mercedes offered goodwill repairs.
Strut towers corrode severely and can break away from the bodywork. Safety-critical defect: the vehicle can drop uncontrollably.
Wheel arches, sills and strut towers rust heavily. Hidden rust forms beneath the sill cladding.
Front and rear strut towers rust through. At the front the towers can break while driving. At the rear this is an economic write-off.
Electronic ignition lock wears out over time. Key turns but vehicle won't start. Problems worsen in cold weather.
Typical electrical problems: alarm system triggers false alerts, cruise control cuts out, air conditioning shows faults. Cable oxidation is frequently the cause.