intake manifolds, oil cooler seals

[Larkone]

Had exactly the same split on mine recently, noticed by the oil mist around it. However no codes and no noticeable drop in performance. Hope it fixes your issue

 

[TeddyRuxpin]

Congrats on tracking down the leak!!

Mine look like the o-rings are failing (I assume there is an o-ring)… I have oil misting on both of mine but apparently that’s ‘normal’???

“They’re only airtight when there’s boost… they all do this” I believe reading…

Seems like a good maintenance item to change after 100k (I’m on 160k) if they’re not too pricey, or at least the ‘hot side’ hose first

How easy is the access for the other (none intercooler) side of the hoses?

 

[MrGreedy]

I took my intercooler off when I changed my aircon condenser the other weekend. No oil misting around the seals on mine (either side of the intercooler), but I changed the seals anyway. Obviously with the bumper and under trays off, access is fine. Getting the bumper off isn't too difficult.
Didn't look at the non-intercooler end I'm afraid as I didn't have those seals.

 

[Larkone]

Changed all of my seals between turbo and IC because of misting oil and it solved the misting issue completely - seals degrade with age and heat.

 

[unclebuck]

Replacing everything from the turbo down to the resonator other side of intercooler onto the throttle flap assy and the egr pipe again. The lot!!!!!!!!

Mercedes only have the one pipe in and no lead time for the other one. So my local motor factors is getting me the gates oe pipes in tomorrow.

Hopefully all will be good this weekend, will fit the new swirl flap motor tonight get that done.

 

[TeddyRuxpin]

Good luck!

Anyone got a part number for the seals and/or for the hoses themselves? Don't think it's the kind of thing you can get on auto doc

I believe one is: 2045280682
The other perhaps: 2045282982

I think 211 models have slightly different ones, with 211 pre-fix. Maybe the 212 shares the C-class 204 prefix?

Looks like they're about £80 each... not cheap, ey. Must be that special, mercedes rubber

 

[unclebuck]

you can get the pipes on autodoc, I didnt use them too fkn slow with the deliveries now. not much price difference getting them from merc, give cardiff a call and give them your reg, ask the for the left and right chargecooler pipes. They are listed as chargecooler pipes and not intercooler pipes on the epc.

 

[unclebuck]

I dont know what your car code is so this is just an example ok, I am not saying these are your correct pipes. you need to find the right ones in there. They are always in the radiator section of the epc.

MBEpc.net

mbepc.net

 

[TeddyRuxpin]

Thanks so much, I tried using the 7zap site and it was useless! Always forget to bookmark this

 

[unclebuck]

Spent this evening trying to remember how to wind a new window regulator cable on the drivers side again. When I did the passenger side it took 2 mins and it was back on, think for one min i could rememebr how tonight!! got it on in the end, the tensioner hasnt come out as much as it did before. Will test fit tomorrow see if it works before putting the glass back in, otherwise back off and reverse the wind and see what happens.

Also as there is no definative info on it, i will make sure if it work to take it apart again ( i must be mad) and re assemble but with pictures for everyones reference.

I found an old thread on the site but it was useless as it dint show direction of winding onto the cog.

 

[unclebuck]

Update:

This evening i put the new swirl flap motor in with new link clips, now the link clips are interesting as they "click" together but that means nothing as they still come apart while you are trying to fit them!!. In the end i grabbed some tamiya liquid glue that i use on model kits and ran a line up the join, and that sorted it, they didn't seperate again. the swirl flap motor had to have a zip tie threaded through the one side and around the other so i could clip one side in first " drivers side" then cut it and was able to put the other side in, three bolts in and its done.

Removed the camshaft breather and replaced it as the seal was worn away, put some oil around the new seal and fitted it in, all bolted down and done.

I was going to fit the new intercooler pipes however i am loosing light here so decided to call it a day and do some more tomorrow.

pics showing the fitted swirl motor, the cam breather and the new pipes " seals pre fitted to new pipes"

 

[unclebuck]

todays update:

fitted the new intercooler pipes, drivers side tested me but I won!! (great success!!)

refitted the turbo ( I am pretty confident it is fine, it has a warranty etc so if i need to it can still go back for inspection)
re attached everything that was loose also new seals etc where needed
All thats left is to bolt the one pipe connector down on the front of the car, put the air boxes on loose, attach the maf and then tighten up the air boxes and get the turbo primed up and then let it idle for 15mins before taking it out.

Hopefully all will be well, I am not holding my breath on it but hopefully.

More tomorrow!

 

[TeddyRuxpin]

Good job! What was tricky about the driver's side hose?

By the way, is that part in the first and second pics above the thing that the PCV connects to? I think they're only about £35-40 from MB and the seal can be an issue. Thinking of changing mine, too.

You must have spent a fortune!!

 

[unclebuck]

Good job! What was tricky about the driver's side hose?

By the way, is that part in the first and second pics above the thing that the PCV connects to? I think they're only about £35-40 from MB and the seal can be an issue. Thinking of changing mine, too.

You must have spent a fortune!!

Yes this is the camshaft breather, it has a 90 degree bend that points upward then the pcv diaphram assy pushes into it, then the pipe off that goes into the side of the maf, will get pics tomorrow.

The drivers side pipe was a pain becuase there isn't much room to get my arm in there, also the metal clip that locks it in had come off and it was a pain to get it back on, took a few goes.

yep spent a fair bit now, rear brakes, front brakes, inner and outer tie rods, gearbox service, had an e and a service inbetween, all the seals from merc along with bolts, new maf, exhaust back pressure sensor, egr seals, front throttle flap and link pipes seals, both intercooler pipes, new turbo, all new gaskets and bolts all around, 02 sensor, new drivers interior carpet, just did the drivers window regulator again also did the passenger a while ago, new swirl flap motor and clips, all glow plugs removed and replaced at a specialists in clevedon ( due back soon for a remove and replace, I am doing this as a preventative measure so they dont bind or break/swell again)

There is more but I can't remember right now!

the only thing's bugging me are the drivers door card has a small bit of worn leather and I need to replace it, I have found one on ebay, I am waiting for a closer picture of the same area of the card, if its good then I will grab it. Also there is a small hole in a bit of the roof liner, it might be able to be repaired, if not then i need to find a new /old roof liner.

Yep all this on a 2008 cls 320, call me crazy.

UB

 

[TeddyRuxpin]

Have you tried using this hand/camera trick this guy uses? Took him 9 minutes to do the whole thing, piece of piss!

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[unclebuck]

update:

Not good news I am afraid.

this morning all that was left was to finish fitting the passenger side intercooler pipe and bolting it to the front of the engine.

Removed the fuel pump relay and primed the turbo 6 times, then put the relay back in.

Started the car and let it idle for a few mins then turned it off to let it settle, got wifey to start the car again and i checked the engine bay for anythng leaking etc, and then i looked down and there was oil everywhere.

The front of the engine was covered in oil spray, all over the belt and pulleys.

On the front of the engine is the oil filter housing that is connected to another aluminium section that bolts to the front of the engine, the intercooler resonator then attached to the front of the engine with an M6x80 hexalobular bolt one the bottom and the top one bolts onto the aluminium casting.

It seems that the old seal had enough and decided to randomly fail and pissed oil everywhere on the front of the engine.

To say i was disheartened is putting it mildly, however, its now off, the seals are very compressed on it so they are the original seals and never changed.

I am ordering a new casting monday from mercedes with new seals, the old one has an issue with the resonator mount , the threads do not look great so I am just going to replace it.
also have to order a load of oil, and I found a slight coolant leak on the pipe from the inlet manifold to the radiator so a new one of those also.

New bolts for the oil filter casting also and hopefully that will sort it out, if anything else happens I don't know what to do then!!

Everything else is back on the car and all is good there.

One last run on this and I am hoping that will be all.

Will update you all as soon as everything is ordered fitted and i fire it up.

 

[unclebuck]

Update:

This afternoon I went back out and decided to take the turbo off again to check things there make sure all was good, i went to bed last night and my mind could't settle and I kept thinking of the turbo oil turret, I almost went out at just before 3am to take a look but wifey was'nt having any of it.

I had re fitted a lot of parts the other day including the turbo and it seems I missed tightening down the two torx 45 bolts that lock the turbo to the oil turret, and with the high pressure oil going through that, it went everywhere, so the oil leak was from there and possibly the front oil filter assembly casting.

I have ordered all new gaskets again and the front casting with new seals, also need a new serpentine belt, oil and coolant.

It was an easy mistake to make, I should have limited the jobs for that day and had a check list.

So this week when everything comes in I will have the checklist ready and will go through the sequence a step at a time and get the one job done first and then so on.

UB

 

[unclebuck]

Could someone with a cls 320 do me a favour?. I need to know the route for the serpentine belt on the front pulleys. I forgot to sketch it down before taking it off. Had a quick look online but didn't find anything. This is for a 2008 cls 320.

Thanks

UB

 

[unclebuck]

Update:

Regarding the boost leak issue, apart from the tear in the pipe, the lower fitting on the drivers side of the intercooler, the spring clip that locks the pipe in was not in its locking slot correctly, this meant the old pipe was able to move in and out of the hole as it was not properly locked in. I found this tonight and have now rectified this. This I am sure is also part of the reason for the continued limp mode P0299 issue, the pipes have been checked and are all locked in properly.

I am hopeful that all will be good once re-assembled!!

Had to wait for parts to arrive, all here now, have to goto cardiff mercedes tomorrow to pick up the front oil filter casting assembly and all new bolts for that and also the resonator ( m5x80 amd m5x26)

I was given a picture of the serpentine belt from the WIS I have added it to the thread for reference for others

As the bolts for the rear of the turbo to the exhaust are new i will reuse them, all the gaskets have been binned and new bought.
The two e45 torx that bolt the turbo to the top of the oil turret are new.

I have all new oil, filter and seals to go on once the oil casting is back on also

I started cleaning the front of the engine this evening before it got to dark, the under tray has oil pooling in the fron of it as the driveway is at a steep angle and the car is pointing downward.

I will drill a small hole in the front of the undertray and put a catch pan underneath to catch the oil, i can then remove the undertray safely and clean underneath as well.

Once it is all back together ( minus undertray, I can spray in a good degreaser and using a soft nozzle setting power wash in the front of that area.

When its cleaned I can fit the new belt and then roll the car out onto the flat and leave it for an hour or so, then check the oil level and top it back up with fresh oil.

I have a checklist to go through so I am not rushing anything.

 

[Petrol Pete]

Have you tried using this hand/camera trick this guy uses? Took him 9 minutes to do the whole thing, piece of piss!

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