C270 intake manifold removal help

[paulinho]

Hi,
1st post here so please be gentle with me please...

I´ve bought a brand new C270 intake manifold because of i have oil dripping from inlet ports.
Does anyone have tried to do such a job here? , what do i have to remove to do such a job?
Thanks, and sorry for my english

 

[markyboys270]

Hello,
If your car is a W203 with a 5 cylinder diesel engine then i can help.

 

[paulinho]

Yep, 5 cylinder 2.7
Am i suposed to remove the fuel rail?

Thanks from Portugal

 

[BlackC55]

Yes and drain the coolant

 

[paulinho]

Yes and drain the coolant

ok...
drain the coolant... because of the fuel cooler?
remove thermostat also?

 

[markyboys270]

Leave thermostat, drain point on radiator, bottom corner at inlet manifold side, take off approximatley 6 litres, catch and re-use.

Before you start, think about new gasket for EGR manifold, the EGR manifold has to come off, or have a good sealing compound available.

You will need MB steering fluid, 0.5 litres because the reservoir has to come out and you will loose oil.

The car needs to be off the ground enough for easy access under the car, not all parts can be taken off from the top.

Have a range of torx sockets and bits.The EGR manifold is held on with 3 bolts needing the torx bit. If you can, use a 1/4 inch (6mm) socket set with a selection of wobble bar extension bars, gives you easier access.

 

[markyboys270]

This is from memory, main parts described, not a difficuilt job just take your time.

Take out fuel filter, steering reservoir and the support bracket.

Take of fuel supply and return lines from bottom of steel pipework.

Take off intercooler hose, mixing chamber and pressure sensor.

Take out EGR valve, (re-use o-ring gasket)

Take out engine oil dipstick, electrical wiring needs unplugged, take single wire from starter motor.

 

[paulinho]

Ok, i think i am almost ready to go with the removal, but just 1 more question.
What parts do i have to do from the bottom of the car? the bottom row manifold bolts?

 

[markyboys270]

Take bolts out of manifold support bracket.

Take bolts out of EGR manifold (torx bit used access from under car)

Lift out EGR manifold or

Take manifold bolts out of cylinder head, most can be taken out from between manifold branches, 2 or 3 bolts taken out from underneath the car.

Lift out as one part. (put back in as one part)

 

[markyboys270]

The engine oil dipstick, fuel lines, starter motor wire, electrical plug on top of gearbox, 2 or 3 manifold bolts and 2 or 3 EGR manifold bolts.

 

[markyboys270]

These are the main steps, anything that i missed you will see for yourself. Just take your time and enjoy.

Remember not to over tighten the bolts on rebuild. You might need hose clips for the fuel lines, about 6 in total.

Good Luck

Mark

 

[paulinho]

These are the main steps, anything that i missed you will see for yourself. Just take your time and enjoy.

Remember not to over tighten the bolts on rebuild. You might need hose clips for the fuel lines, about 6 in total.

Good Luck

Mark

Thanks for all the help, i will give it ago

Paulo

 

[paulinho]

Have done... jesus what a job!!!
Most of my inkake ports where closed , after the repair the car is much better on medium to high revs.
Have done a test in my "privat road" and reached a top speed of 252km/h (on a straight road), and the time that toke to get to that speed was very short.
My car mods are : ECU mod by MBpower (best of the best here in portugal), K&N air filter, EGR mod (Thanks mbclub.co.uk), decat (the middle of the car one).
Never thought that a C270 could get to that speed.
Thanks VERY much to those who helped me here .

By the way : EGR mod to 2001 C270 is REALLY simple (the 3 wires envolved have yellow) .

Paulo

 

[markyboys270]

Good to know all went well.
My manifold was blocked with carbon, the linkages were also broken.
252 kph = 157 mph = pretty dam fast ! I took my e270 up to 130 mph and it immediatley broke, ha! ha!.
All sorted now, had to decat 1 and 2 and a fit a new turbo (oil seal failure, going to rebuid and keep for spare).
Heavy snow here is stopping a road test but i guess everything should be fine.

Happy motoring ! :bannana:

 

[paulinho]

Good to know all went well.
My manifold was blocked with carbon, the linkages were also broken.
252 kph = 157 mph = pretty dam fast ! I took my e270 up to 130 mph and it immediatley broke, ha! ha!.
All sorted now, had to decat 1 and 2 and a fit a new turbo (oil seal failure, going to rebuid and keep for spare).
Heavy snow here is stopping a road test but i guess everything should be fine.

Happy motoring ! :bannana:

I am tempted to remove the first turbo also but i´ve heard that car doesnt go well without both cats
What is your first impressions with both removed?

Cheers
Paulo

 

[Jett]

Hi Paulinho
I'm from South Africa driving a 2004 C270 CDI.I see that you have replaced your intake mainfold with a new one. The seals on mine were leaking as well. I'm trying to locate a new as well. The prices in South Africa are ridiculous around R12000.00 from Mercedes Benz. Where did you locate one? Price ? Contact details please?
I've also replaced o'rings on the fuel pump and the rear oil seal on the pump, so If you need advice on that, please ask. Thanks

 

[kwakdonut]

I am tempted to remove the first turbo also but i´ve heard that car doesnt go well without both cats
What is your first impressions with both removed?

Cheers
Paulo

First turbo? Must be a typo! Am sure you mean first cat....

 

[paulinho]

Hi Paulinho
I'm from South Africa driving a 2004 C270 CDI.I see that you have replaced your intake mainfold with a new one. The seals on mine were leaking as well. I'm trying to locate a new as well. The prices in South Africa are ridiculous around R12000.00 from Mercedes Benz. Where did you locate one? Price ? Contact details please?
I've also replaced o'rings on the fuel pump and the rear oil seal on the pump, so If you need advice on that, please ask. Thanks

Bought from mercedes for 400 euros, already replaced o´rings but thanks.

 

[paulinho]

First turbo? Must be a typo! Am sure you mean first cat....

Hehe, yep first cat. .
But would be good to have 2 turbos like the new C250
I am trying to imagine that in my 2.7

 

[markyboys270]

Hello Jet,
Remove the manifold flaps completley, close up the spindle holes with a bolt, washer and two nuts, (after filling up with silicon), keep the stepper motor connected and the car will run fine.