2003 E320 CDI S210 running problems

[johnb]

Hi
Just picked up a 2003 E320 CDI with 175K on the clock. A few problems have come to light on the drive home (about 250 miles).

1. Glow plug light stays on after engine starts from cold, then clears and doesn't reappear on hot start.
I'm guessing glow plugs down?

2. Black smoke when starting and driving while in warm up phase, seems to clear once warm.

3. Revs quiet happily for the first mile or so, but then goes in to limp mode - will not rev past 3K, restart clears it, then goes in to limp again etc lack of power etc made for fun on the motorway hills :-(

4. Engine temp seems to run at about just below 60 degs - it never seems to fully warm up.

Everything works on the car, the gearbox is perfect, and the main display shows 'No Malfunction'

Oh...drivers side headlight pattern is very weird, these are standard halogen lights.

So overall happy with the car, just needs some TLC on small rust spots (no surprises there then!) and the tailgate handle is sticky and needs to be flicked out - strip and clean should sort that.

Advise and suggestions gratefully received,

Many thanks
John

 

[Timster]

Glow plug light - probably a glow plug out.

Limp mode - you should get the codes read

Boot handle - as you say easy fix, you just have to dismantle the boot lining to get at it. Not a huge job. Common problem!

Awesome cars. Good luck with it. Just written off an e220cdi, picking up a 320cdi on Tuesday. Both s210's - nothing else ticks all the boxes quite the same!!

 

[mersum1es]

New thermostat needed, you head light bulb may not be correctly in its place.

Might be a turbo problem, but codes will tell.

 

[johnb]

Just read the codes - there are none! Lots of live data to watch thou!
Using Gendan engine check with an Elm interface and a round to rectangular adapter.

Going to go for a MAF change (pierburg) and a EGR clean.

Checked the headlight and the bulb is hanging out of the back of the headlight!
Not sure what should be there to hold it in place, only a bulb pushed into the wiring harness, the doesnt seem to be any clippage present, anyone got a picture of the gubbins on the back of a halogen headlight?

 

[Timster]

Strange that there are no codes but it's going to limp - if it was me I'd put it on STAR somewhere. It's the only way to be sure! Let me know if you need any parts. I'm going to have my recently written off one in my driveway for the next few months as a donor car. It had zenon lights.

Which one do you need as I have lots of spares and think I have a drivers side halogen complete unit ....

 

[pimpdriver]

I got my stat changed last week. £114 all in. Well happy

 

[bob6600]

You need to get it on a better code reader (STAR is advisable)

The black smoke could just be from the EGR, we are all guessing until it gets diagnosed

The thermostat needs changing - there is a DIY on this somewhere and it is a simple job

As for the glow plug, it will either be one or more faulty plugs (likely) or could be the glow plug relay (unlikely) but will be clearer after a diagnosis

 

[guydewdney]

the carsoft type readers work well on the 210's - cheap enough on fleabay

 

[johnb]

drivers side headlight has the problem.

 

[Dieselman]

I suspect eh limp home and black smoke are EGR related. If not, it is likely the inlet port shut-off flaps are stuck.

 

[johnb]

Just borrowed another code reader, a snap on one, and again it shows me live data etc, but no error codes stored or pending. Is it possible for the car to run in limp mode without logging any fault codes?

 

[bob6600]

The MAF does not always log an error, but in STAR the live data can determine if it is faulty or not (IIRC there is a specific test)

 

[W210Virgin]

Checked the headlight and the bulb is hanging out of the back of the headlight!
Not sure what should be there to hold it in place, only a bulb pushed into the wiring harness, the doesnt seem to be any clippage present, anyone got a picture of the gubbins on the back of a halogen headlight?

You should have a spring clip type thingy in there to keep the bulb in and a lid on the back of the headlight to seal it up. Get some bits from a scrapper.

 

[johnb]

Well, fixed the boot lock handle with copious WD40 (Others are available)

Cleaned the crap out of the Air Mass Sensor with electrical cleaner an i2s sensor part number 7.22684.07 in there. Yet to drive it on open road but seems happier.

Discovered a dose of the 'black death' around injector 3, will deal with that later. Looks like black shiny lava, not yet over the clamp or bolt.

 

[johnb]

Well better, but not right.
So just removed the entire EGR valve and found it to be packed solid, the vacuum actuator was packed with black fine dust, and unable to move, and the valve itself was blocked with goop. Didn't initially realise it had two ports, but some digging and poking sorted that out, plus a good wash in diesel.

Checked the glow plugs and found that only one was working, so I will order some up tomorrow, got a new peirburg air mass sensor, so I will fit that, checked the turbo, looks good, VNT actuator is free to move, very minor axial play in the turbine shaft, and the compressor turbine looks nice and clean, and no oil left in the inlet port.

Got to sort the black death out - job for another day, not blowing gasses at mo - checked with a spray of WD40 with engine running.

So, just got to reassemble and go for a blast.

John

 

[W210Virgin]

Busy weekend then, eh?

 

[bob6600]

So just removed the entire EGR valve and found it to be packed solid, the vacuum actuator was packed with black fine dust, and unable to move, and the valve itself was blocked with goop. Didn't initially realise it had two ports, but some digging and poking sorted that out, plus a good wash in diesel.

Once you have cleaned this, do the EGR shunt/mod, it will prevent this happening again

 

[johnb]

Yes, busy Sunday, not too bad a job. i think it has been out before as the bolts had been shuffled around, engine and engine bay needs a damn good clean, very dirty. I'll have a go at it with some TFR and warm water.

The car now runs as it should, just got to fit the glow plugs, managed to get hold of 2 and replace them. Heart in mouth as I undid them...very tight, but they came out OK once cracked. The other 4 to follow.

Car still running cool so just ordered a new thermostat from ECP.

Next an oil and filter change, and then go to work on the various rust scabs.

Lovely car to drive.
John

 

[johnb]

Spoke too soon, car back in limp mode after a few miles. Fine on restart, drive a few miles and it drops down to limp. No warning lights, interestingly cruise control still works, but no kick down, revs max limit at 3k and 3/4 throttle tends to hang about at 2k with a slight surging as if she is trying to go...but can't.

Got to get it on some diags, just begrudge spending the £50 or so my local indies want for a look see with STAR.

So far:
New pierburg air mass sensor (which is marked up as i2s)
Cleaned and checked operation of EGR valve (Totally blocked up with goop)
New glow plugs. (All were knackered)

 

[Timster]

Sorry - Can't help you with whats wrong, but can help with parts. Am breaking a complete S210 E220 cdi so if you need any bits let me know.

Good luck getting it running - great cars when they go!