Stuck with "black death" & cow boy mechanic job. Please help!

[Luded755]

Hi guys,

Big hello to everyone as it's my very first time here.

I have just bought w210 320cDi with 90k on the clock.
Only 1 owner car and it's a mint apart for one problem "black death".

Last owner explained to me that injector 3 is stuck as he tried to get it fixed but the mechanic couldn't do it so he decided to sell it. He was quite old guy and you could tell he wasnt interested in the car anymore. (Mechanic was mobile mechanic & that explains).

When I inspected the car. Injector 3&4 had worst case of black death. Literally covered with black stuff. Even worst thing was both injectors had 12mm strange looking normal bolts instead of the 6m stretch bolts. Engine would start without any problem but brownish smoke which could cover the whole street within minutes. Car was not safe to drive so I decided to call mate of mine. He's aa mechanic. We both came to conclusion that smoke is unburnt fuel (diesel) as it wasn't blue/white or black and no evidence of mixture of oil and coolant anywhere. And towed the car home.

I started taking the injectors out this morning. All injectors came out with a bit of struggle but injector 3&4 won't move the slightest. The trouble is I can not run the engine prior to take the injectors out as it smokes really bad. Any suggestions how to take these out please?

Secondly, that mobile mechanic deserves life time sentence!!! As he replaced the stretch bolts with normal 12mm size very big threaded bolt's. He has also damaged good 1" of the threads of heilcoil. I know stretch bolts are very important but guys is there a way to actually replace them? Is it possible? Or what should be done ? Suggestions please?

Lastly, this heavy smoke indicates bad injector. My doubt is cylinder 3 or 4. Shall I get them replaced? Or get them refurbished? Suggestions please?

Thank you very much for your time guys and I hope so see some genius ideas now.
Regards.

 

[a111r]

I have a spare OM613 head part from a dismantled engine... that might solve this problem.
I will have a look tomorrow.

 

[Alps]

where in the country are you as there are some very good indies on here who deal with this issue on a daily basis.

 

[BlackC55]

Any decent garage will have the necesary pullers for the bosch injectors. There are also mobile thread repair specialists that can do this kind of work too.

 

[bob6600]

If you want to return it back to normal, you may need to replace the head as I'm not sure you can go down from 12mm to 6mm with inserts.

Are you sure it is an M12? I had a bodged M10 and it was touching the injector, don't think an M12 would fit.

Eventually I bought a hex headed bolt and it has held for nearly 3 years. I know it is not recommended as there are stories of injectors shooting at bonnets.

 

[coneybiller]

You'll need a special slide hammer that clamps round the injector and hammers the injector out in an upward motion. I've heard of using Mr muscle oven cleaner all around the affected area and to leave it to soak for a few hours. Could help alleviate the situation. But I would imagine the slide hammer is going to be the best bet!
Once out and thourghly cleaned and re-instated back to norm, it'll probs want a leak off test carrying out to determine the knackered injector. It's a possibility that it's smoking heavily due to the injector not sealing correctly and most of the air inside the cylinder is escaping, meaning it'll burn the fuel with next to no air hence the smoke!
As for the bolts, it's not looking good! Only thing I can think of, is continue led with that size bolt but make sure it's the same length as the original bolts perhaps?

 

[sprinter316]

Got to love, just half the story, the ole boy prob didn't want to spend a large amount having it done properly,

Any way , it's a crap design and it does need 6mm bolts and there's a reason form the thread being so low , so,12 mm bolt is never going to work as it will tip injector off seat.

As for mr muscle if it works it ain't stuck,
If they are properly stuck nothin with penetrate, however with the right hydraulic equipment not it will,come out , and the head can be restored back to normal,spec,
Interesting , no one mentioned the rocker valve cover, ponder that one.

We do these day in day out and ave seen it all

 

[Luded755]

Well, thank you everyone for the responses. Appreciate it.
I have managed to take all injectors out. MR MUSCLE OVEN CLEANER is to use! Works like magic. Also found out that when the previous guy tried to take the injector #4 out he damaged the rocker cover! taking it tomorrow for welding now.
My apologies guys. The bolt which he has used i's 9mm not 12mm. He used 9mm bolt which is barely 1" deep. After 1" it has original threads of 6mm. Tricky one eh?

I am based just outside Cardiff so if someone knows a garage where I can take my injectors will be handy.

Thank you.
Regards

 

[Luded755]

Hello again,
Desperate for some advice please guys.
I have managed to replace the injectors and sorted the bolts and everything but the smoke isn't disappearing.
It has decreased to 30% from before but not finished completely.
Also, the fuel filter has been bypassed from the previous owner. Would it effect fuel pressure?
On idle car does not smoke at all. As soon as you take it for a drive it smokes. It takes good minute or 2 to get back to normal (no smoke) on idle again. It is brownish white smoke.
No power loss or anything. Turbo kicks in strong too.
Please advice. .
Regards

 

[ADR1AN]

Has it been badly remapped? Just a thought. Not sure how you would check that either.

 

[a111r]

The fuel filter has been by-passed, you say?

I wonder for how long, as they're not there for ornament?

 

[Luded755]

No don't think so. Tomorrow I am going to check all the injector seals again. Connect the fuel filter back and also there is some strange squeky noise from engine bay. It's close to fuel regulator. Will try to check that too. Gutted about this issue! Some mechanic also said it's from the previous diesel leak from injector because one of the injector was broken inside and it needs to be burnt out. But it's way to smokey to drive. Clueless now!!

 

[a111r]

I've got most of an OM613 engine in bits, if you need any parts.

 

[bob6600]

Fuel filter is there for a reason, can you re-instate it?

Replacement injectors - were they new? Correct numbers?

 

[QUTSELL]

I have exactly the same problem,posted on here in another question and answer,but beginning to understand what the problem is now,i was going for the air flow,decided now to run a diagnostic check.

 

[Luded755]

Thank you for reply again.
Yes, fuel filter was bypassed. Now I have managed to put it back how it is supposed to be. Injectors were tested and refurbed and retested. Thank you A111r. I shall give you message if I need something. Just put it back together taking for spin in 1 hour. Will give you the update.
Thanks.

 

[Luded755]

Well, just done 10 miles. Smoke has decreased alot. On the way back when I was only mile away from home I thought let's put the foot down and see. Well!! Power didn't drop or anything but EPC light came on. No power cut off or anything. Drove exactly normal (same as before). Got home restarted and the caution is gone. Now I wonder why did the old guy bypassed fuel filter? He might had this issue before?
Silly question please If someone can answer. there is an arrow sign on the fuel filter, which direction should this arrow/flow of fuel should be going? Back to the fuel tank or in the fuel rail?

Also, is there a way of testing high pressure pump please?

Thank you guys! Appreciate your answers

 

[PobodY]

Surely the arrow should indicate the direction of flow; usually from the pump to the fuel rail. - No point in filtering the fuel after it has been through the rail; you want to stop the crap getting in to the injectors and clogging them.

 

[bob6600]

OK so we know why the filter was by-passed.

It is most likely worn O-rings, brittle pipes or both. If the clear pipes look yellow, I would change them