Mercedes Benz Classics: Owners Operation, Service, and Repair Workshop Manuals

Mercedes OM616 Diesel Engine Manual

The Mercedes Benz 2.4L OM616 Diesel Engines 1973 to 1985+

Download: Mercedes Benz OM616 Engine Motor Manuals

Mercedes Benz OM616 Engine ManualMercedes OM616 Diesel Engine Manual
Download: 53.6mb, flash, .pdf
Application: W115, W123, W460, W631-MB100

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Mercedes OM616 Diesel Motor Workshop ManualsIn 1982, India Bajaj Tempo, now Force Motors, signed a deal with Daimler Benz to manufacture the OM616 Mercedes engine for fitting in its line of vehicles. This Mercedes engine gave the company a technological edge over other Indian manufacturers leading to the success of several Bajaj Tempo models.

The OM616 engine family is a diesel automobile Inline-four engine that Mercedes-Benz used in the 1970s and 1980s, and has been produced by Force Motors in India from the 1980s to the present. This engine was used in various cars, vans and Unimogs over its production lifetime, and still finds use in Force Motors SUVs.

The abbreviation ¨OM¨ stands for ¨Oel-Motor¨ (Oil Motor) "Diesel", which refers to the fact that it runs on oil. This method of naming is still used on Mercedes-Benz diesel engines today.

The Mercedes-Benz OM616 engine was a 2.4 L (2,404 cc) engine with power output of 48 kW (64 hp). In August 1978 the pre-combustion chamber was updated for more swirl and more efficient combustion. The new camshaft pushes the valves deeper so the air and smoke gases have less resistance. The engine capacity was lowered to 2.4 L (2,399 cc) to satisfy engine displacement tax laws in Europe, but power output rose to 54 kW (72 hp). A similar power update around this time was also done on the OM615 and OM617 engines.

The Mercedes OM 616 and its variants still power the light commercial vehicles of Bajaj Tempo, including the Tempo Traveller, the new Excel series of trucks and the Trax range of multi-utility vehicles. At present, Force Motors is also assembling other Mercedes engines and supplying it to Mercedes Benz India Ltd.

Mercedes OM616 Engine Service Repair Manual

Version Application Survey OM616 Diesel Engines

Mercedes OM616 Engine Long BlockOM616.912 63 kW (84 hp)

  • 1976-1978 W123 (240D)

OM616.916 48 kW (64 hp)

  • 1973-1976 W115 (240D)
  • 1976-1985 W123 (240D)

OM616.936 53 kW (71 hp)

  • TN Transporter
  • G-Class

OM616.937 53 kW (71 hp)

  • TN Transporter

Later, more powerful versions of the OM616 are interchangeable with early ones. This is done with many older transporter vans and campers like the 207D and 307D models. It is not possible to change only the cylinder head for one with the higher rating, since the higher valve lift of the later versions will interfere with the early pistons.

Engine Year Model
OM616.912 1979-1985 Mercedes Benz W123 240D
OM616.913 197-1985 Mercedes Benz TN
OM616.916 1973-1977 Mercedes Benz W114/W115
OM616.916 1977-1985 Mercedes Benz TN
OM616.916 1976-1986 Mercedes Benz W123 240D
OM616.936 1973-1995 Mercedes Benz TN
OM616.936 1979-1991 Mercedes Benz G-Class W460
OM616.936 1981-1995 Mercedes Benz W631 MB100
OM616.937 1979-1985 Mercedes Benz TN

The Bajaj Tempo OM616 engine is configured for different power outputs depending on the intended usage, from a 65 bhp (48 kW) version, to the 91 bhp (68 kW) Turbocharged version used in the Trax Gurkha (Which is superficially similar to the Geländewagen design).

Mercedes OM616 Engine Motor

OM616 Engine Variants Specs

  • Model OM616 Type 4 Cylinder, 4-Stroke
  • Air filter Oil Bath Type
  • Oil filter Bye pass flow type paper filter
  • Fuel filter Dual filter
  • Oil sump capacity 6.5 L (6.9 US qt; 5.7 imp qt)
Variants Cam CCM Cylinders Valve Comp. Perform Torque Bore Stroke Production
OM616.912 OHC 2 399 4 In-Line 8 21 : 1 53 kW 137 Nm 90.9 x 92.4 1979 - 1985
OM616.913 OHC 2 399 4 In-Line 8 21 : 1 53 kW 137 Nm 90.9 x 92.4 1979 - 1985
OM616.916 OHC 2 404 4 In-Line 8 21 : 1 48 kW 137 Nm 91 x 92.4 1973 - 1976
OM616.916 OHC 2 404 4 In-Line 8 21 : 1 48 kW 137 Nm 91 x 92.4 1976 - 1985
OM616.936 OHC 2 399 4 In-Line 8 21.5 : 1 55 kW 137 Nm 90.9 x 92.4 1973 - 1995
OM616.937 OHC 2 399 4 In-Line 8 21.5 : 1 53 kW 137 Nm   1979 - 1985