Mercedes Vario 512DEngine Rebuild— From £2,200
Specialist Mercedes Vario 512D engine rebuilds and replacements, with registration-based engine matching, nationwide recovery and a 12-month unlimited-mileage warranty
Rated Mercedes Engine Specialists — 1,800+ Engines Rebuilt
Specialist technicians with 10-15 years of experience
12 Month Unlimited-Mileage Warranty
Nationwide Recovery
Free Engine Matching by Registration
M256 Specialists
Your Mercedes Vario 512D Engine
Vehicle
Mercedes Vario 512D
Model
Vario
Variant
Vario 512D
Fuel
Diesel
Engine
OM602 or OM611
Capacity
2.9L/2.2L
Generation
Single generation, lighter chassis (1996–2013)
Rebuild From
£2,200
Not sure which engine you have?
The VARIO 512D uses the M256 3.0-litre inline-six mild-hybrid engine — enter your registration below and we'll confirm your exact spec before you get a quote.
DVLA & VIN verified
100% secure & private
No obligation quote
Mercedes Vario 512DEngine Rebuild Price
Starting From £2,200
Engine Code
OM602Rebuild From
£2,200
Generation
Single generation, lighter chassis (1996–2013)
Engine Code
OM611Rebuild From
£2,200
Generation
Single generation, lighter chassis (1996–2013)
Exact price depends on condition and parts required — submit your reg for a fixed-price quote.
Mercedes Vario 512D Injector Seal & Timing Chain Wear
Vario 512D engines — OM602 and OM611, across the full production run — commonly show injector seal and timing chain/gear wear over time. This pattern is shared with the equivalent-era Sprinter and is well documented across Mercedes commercial vehicle specialist circles. We replace injector seals, timing chain components, timing gears and gaskets as standard on every Vario 512D rebuild.
include_in_hero_hook: yes — Source: established specialist pattern (per G-BRF), shared with equivalent-era Sprinter. Applies to both OM602 and OM611 — the same pattern is confirmed across the range.
Source: established specialist pattern (per G-BRF), shared with equivalent-era Sprinter. Applies to both OM602 and OM611 — the same pattern is confirmed across the range
Mercedes Vario 512DENGINE OPTIONS
Every VARIO 512D is different. That's why we offer the right solution for your engine, your car and your budget.
REBUILDING YOUR VARIO 512D ENGINE
We rebuild the engine your VARIO 512D already has instead of selling you a used engine of unknown history — strip it down, pressure-test it, and replace every worn or damaged component (timing chains, bearings, water pump, gaskets) with updated OEM parts. Near-new performance with a 12-month unlimited-mileage warranty.
From £3,200RECONDITIONED VARIO 512D ENGINES
A full strip-down, inspection and replacement of worn parts rather than a straight swap. If that's what you're after, our rebuild service is exactly that.
Learn moreREFURBISHED VARIO 512D ENGINES
Restoring your existing engine to full working condition rather than replacing it outright. Our rebuild service covers this.
Learn moreREMANUFACTURED VARIO 512D ENGINES
Built to original specification with updated components. That's consistent with what our rebuild service delivers on the M256.
Learn moreREPLACEMENT VARIO 512D ENGINES
If your existing engine is beyond economical repair, we offer complete engine replacement and fitting – sourced and fitted by our team, with the same 12-month warranty.
Learn moreUSED VARIO 512D ENGINES
Matched low-mileage used engines for when time is critical. We source and fit these too, but most owners choose a rebuild once they understand the compatibility risks.
Learn moreNOT SURE WHICH OPTION IS RIGHT FOR YOU?
Enter your registration below and we'll confirm your M256 and talk you through the best solution for your VARIO 512D, honestly.
Ask About Your Options
OUR WORKSHOP
01RECOVERY COLLECTION
02M256 ENGINE STRIPPED FOR REBUILD INSPECTION
03VALVE COVERS & COOLANT COMPONENT WORK
04TECHNICIANS AT WORK
05ENGINE TESTING (RIG)
06COMPLETED & READY FOR REFIT
Real photos from our workshop — not stock imagery. This is what a genuine Mercedes Vario 512D rebuild looks like.
Mercedes Vario 512D ENGINE REBUILD PROCESS
WHAT MERCEDES VARIO 512D OWNERS SAY
WE COVER YOUREXACT VEHICLE
Enter your registration below and we'll confirm your VARIO 512D has the M256, along with an exact rebuild price.
WHY MERCEDES VARIO 512D OWNERS CHOOSE US
Engine matched using VIN or registration number — confirms OM602 vs OM611 before you're quoted
Genuine specialist workshop — not a broker
Specialist technicians with 10-15 years of experience
We don't swap your engine for an unknown used unit
Nationwide recovery, workshop rebuild
12 month unlimited-mileage warranty
All engine ancillaries serviced as part of the rebuild
Trade & public enquiries welcome
Dedicated advisor from quote to fit
OUR MOST RECENTMERCEDES RECOVERIES & REBUILDS
Real vehicles brought into our workshop. Open bonnets, stripped blocks, and cars ready for collection — this is what genuine engine work looks like.
Mercedes Vario 512D
RECOVERY
Mercedes Vario 63
DIAGNOSTICS
Mercedes Vario
STRIPPED ENGINE
Mercedes Vario S
TIMING CHAIN REPLACEMENT
Mercedes Vario 512D
IN FOR REBUILD
Mercedes Vario C
REBUILD IN PROGRESS
HOW IT WORKS
SEND YOURREGISTRATION
RECEIVE YOURFIXED-PRICE QUOTE
WE RECOVERYOUR CAR
REBUILD &REFIT
Most Vario models are recovered within a few hours of booking. Most rebuilds are completed within 3-5 working days.
Workshop slots fill up fast — book your recovery today.
LOOKING FOR A USED ORREPLACEMENT ENGINEINSTEAD?
We supply low-mileage, VIN-matched used units too, and offer full replacement and fitting. However, most VARIO 512D owners choose a rebuild once they realise it removes compatibility risk and works out more cost-effective over the life of the car.
Enter your reg below — we'll show you every option, honestly.
ABOUT THE MERCEDES VARIO 512D ENGINE
The Vario 512D is part of the lighter-chassis Vario range, produced from 1996 to 2013. It used two engines across its production run: the OM602, a 2.9-litre inline-five diesel, and the later OM611, a 2.2-litre inline-four diesel. Both are well-proven commercial diesel units shared with the equivalent-era Sprinter, and both share the same known wear pattern — timing chain and gear wear, and injector seal deterioration over time. The Vario range was discontinued in 2013, but we continue to rebuild and replace engines for every one still on the road.
We continue to rebuild and replace M256 engines for every VARIO 512D on the road.
MERCEDES VARIO 512D ENGINE CODES
A 2.9-litre inline-five diesel fitted to the Vario 512D from 1996 onwards. Known for injector seal and timing chain/gear wear — see the callout above. We replace timing chain components, timing gears, injector seals and gaskets as standard on every OM602 rebuild.
Check Your OM602 Vario 512DA 2.2-litre inline-four diesel fitted to the Vario 512D from the late 1990s onward, as a lighter alternative to the OM602. Known for the same injector seal and timing chain/gear wear pattern as the OM602 — see the callout above. We replace the same components as standard on every OM611 rebuild.
Check Your OM611 Vario 512DMERCEDES VARIO 512D ENGINE COMPATIBILITY
The Vario 512D spans two engine codes across its production run, with the same known wear pattern applying to both. Before we quote or supply anything, we confirm:
Your exact engine code (M256) via registration or VIN
Your generation (R190)
Drivetrain and ancillary specification
Any electronics or ECU considerations specific to your exact build
This is why we always start with your registration rather than a generic Vario quote — it protects you from paying for parts that don't fit your actual car.
MERCEDES VARIO 512D ENGINES BY YEAR
From the R190's launch in 2023, the VARIO 512D has used the M256 3.0-litre inline-six mild hybrid throughout. If you're unsure of your exact spec, we'll confirm it before you book.
The M256 has been fitted to every VARIO 512D since launch — if your registration year isn't listed above, get in touch and we'll confirm availability directly against your reg.
WE COVER EVERY MERCEDES VARIO 512D MODEL YEAR:
Mercedes Vario 512D
1996 Engine Rebuild
Mercedes Vario 512D
1997 Engine Rebuild
Mercedes Vario 512D
1998 Engine Rebuild
Mercedes Vario 512D
1999 Engine Rebuild
Mercedes Vario 512D
2000 Engine Rebuild
Mercedes Vario 512D
2001 Engine Rebuild
Mercedes Vario 512D
2002 Engine Rebuild
Mercedes Vario 512D
2003 Engine Rebuild
Mercedes Vario 512D
2004 Engine Rebuild
Mercedes Vario 512D
2005 Engine Rebuild
Mercedes Vario 512D
2006 Engine Rebuild
Mercedes Vario 512D
2007 Engine Rebuild
Mercedes Vario 512D
2008 Engine Rebuild
Mercedes Vario 512D
2009 Engine Rebuild
Mercedes Vario 512D
2010 Engine Rebuild
Mercedes Vario 512D
2011 Engine Rebuild
Mercedes Vario 512D
2012 Engine Rebuild
Mercedes Vario 512D
2013 Engine Rebuild
If your registration year isn't listed above, get in touch — we'll confirm availability directly against your reg.
MERCEDES VARIO 512D ENGINE COSTS
A Mercedes Vario 512D engine rebuild starts from
£2,200
A full replacement engine and fitting service is also available. Exact pricing depends on the condition of your existing engine and the parts required — submit your registration for a fixed-price quote within 30 minutes.
12 MONTH
UNLIMITED-MILEAGE
WARRANTY
MERCEDES VARIO 512D ENGINE SIZES
• Mercedes Vario 512D 3.0 Litre Engine (M256, I6)
MERCEDES VARIO 512D FUEL TYPES
• Mercedes Vario 512D Petrol Mild Hybrid Engine Rebuilds
RELATED MERCEDES VARIO VARIANTS
Most Mercedes Vario engine rebuilds are completed within 3-5 working days.
Nationwide recovery and collection available for all Vario models.