Engine Overview and Common Failures
The weight of the OM642 engine assembly is 220 kg. The engine number is located at the front, at the junction of the block and the head. There are leaks in the heat exchanger. The most well-known problem with this diesel engine is the leaks in the heat exchanger gaskets, and since it is located in the block assembly, replacing the inexpensive gaskets can be costly. In approximately 2010, the design was improved and similar leaks are no longer encountered.
The power unit is equipped with a reliable Common Rail fuel system from Bosch, but its piezo injectors are very demanding in terms of fuel quality and are also expensive. It is also worth noting the regular failures of the fuel quantity control valve in the fuel pump.
In the intake manifold of this power unit, there are steel swirl flaps, but they are controlled by servo drives with plastic rods, which often break. The problem is exacerbated by contamination in the intake due to the weak VKG membrane.
The turbocharger itself, produced by Garrett, is very durable and runs smoothly up to 300,000 km, except that the system for changing its geometry often gets stuck due to severe contamination. Most often, the turbine is damaged by debris from the destruction of the welded joints of the exhaust manifold.
Other problems with this engine include frequent oil leaks and a not very durable oil pump, and since it is sensitive to oil pressure, bearing wear is not uncommon.