intake manifolds, oil cooler seals

[unclebuck]

update:

Almost 3 hours to put one bolt into the turbo to crankcase bracket and tighten it down , dropping two onto the undertray all because you need origami fingers to get it in there!!
Swearing, rain and more swearing was undertaken.... however the turbo is back in with all new gaskets, for some reason today was made to task me!

Tomorrow the rear turbo pipe to exhaust then its onto the front.

 

[unclebuck]

Update:

Busy day today, finished installing the egr pipe and the turbo to exhaust connection, the back pressure sensor, maf, air boxes and re connections.

Fitted the new oil filter housing assembly, 4 bolts at 14Nm also the new intercooler pipes and new bolts for the resonator, coule of new seals as well.

I got under the front of the car and drilled asmall hole in the front of the undertray and drained the last remnants of oil from the tray.

Once the oil was done I removed the undertray and coated it with a degreaser and loads of fairy liquid! Got the pressure washer ready with a low power wand.
While it was soaking i degreased and cleaned all the pulleys and then fitted the new serpentine belt, once this was done i used the washer on teh front of the block and the lower area and cleaned everything up.

Once everything was done the car was put into neutral with the fuel pump relay out and then rolled out and oushed back onto the road so the oil can settle overnight level and i can check it in the morning to top it off.

Only other thing to do is have the coolant changed and a replacement pipe from the inlet manifold on the drivers side to the radiator.

So hopefully tomorrow after topping the oil off with new I can prime the turbo and start things up and let it idle.

Fingers crossed!!!!!

UB

 

[unclebuck]

update:

Checked the oil level and filled as needed, primed the turbo and engine 6 times then replaced fuel pump relay and started car and let it idle.

Checked for leaks, no leaks, checked for any fluid leak, nothing.

Took car out for a gentle drive and it was fine, stopped at a junction and pulled away slowly as i didnt want to push things too soon, and as i turned right.. limp mode!

So something else is triggering this p0299 issue as at the time the rev counter was way under 10x and i was just gently turning right from the junction so the turbo was not being pushed.

After everything I have done now I have no choice but to get it to Mercedes as there is something else triggering this error now.

Also got another new code of P0098 intake air temperature sensor 2 circuit high which is usually linked to the maf, however this is a brand new maf from mercedes.

I have gone as far as I can with this now, so lets see what Mercedes finds.

I wish it was better news but this has beaten me now.

Will update the thread when I know more myself.

Many thanks to everyone for their advice and checking in along the way.

UB

 

[Larkone]

Check the wiring and plugs to those sensors - could be poor continuity in a cable or plug

 

[unclebuck]

Check the wiring and plugs to those sensors - could be poor continuity in a cable or plug

Did that mate, all is good, i even had my old batwing still so plugged that in as i know that is and still was ok. when i plug the obd2 in the inet air temp shows -40. It needs to be put on a star again, cleared, the ecu checked and if any updates needed get them done. make sure the new maf is ok if not then it needs to be changed as i got it from mercedes. there is a load of other grey codes that need clearing also but they were expected as the car had to be moved with things disconnected with power on.

Lets see what mercedes finds and take it from there, it may all be something really simple or i forgot to plug something in somewhere, they will find it quicker than me.

I really need a break from messing with the car now.

 

[unclebuck]

Check the wiring and plugs to those sensors - could be poor continuity in a cable or plug

@Larkone the air intake temp sensor cable had slid back off, bloody thing. all loked in and good there. just the p0299 for merc to sort out now. mind you was boosting lovely today, so i am thinking a connector issue somewhere now. they will find it quicker than me.

 

[W1ghty]

Well done for all your work buddy , I think if anything , having seen what you have been through when my cooler seals go I’ll get an Indy to do it

 

[unclebuck]

Well done for all your work buddy , I think if anything , having seen what you have been through when my cooler seals go I’ll get an Indy to do it

To be honest i have enjoyed it as much as hated it on times however, with what i have learned as I went along it was worth it, besides that I did save a lot of labour charges in the end.

This p0299 issue has to be something simple now more than likely, if they say it is the turbo at least its under warranty and can go back, I will just bite the bullet and let merc put a new one on then, get my money back on the other one.

we will see what happens!

Thanks

UB

 

[BlackC55]

Thats a low boost code. Maybe it just needs its adaptions re-set. MB will be awkward in looking at it because you have done the work yourself. I admire it, they won't.
Use an independent near you. I promise you it will be a better outcome.

 

[BlackC55]

The adaption data must be re-set after this kind of work.
Glad you enjoyed doing it, we were doing one a week last year....

 

[unclebuck]

The adaption data must be re-set after this` kind of work.
Glad you enjoyed doing it, we were doing one a week last year....

Thanks for the info

Update:

Coming home from work just now and she boosted fine, a couple of times i had to back of the throttle and then kick down and it would boost fine, the same in sport mode,
first time it has behaved.

I am hoping it is the same tomorrow morning, either way I am off the merc cardiff tomorrow to speak to them as they were supposed to call me tuesday morning and never bothered.

Also I may pop to Avantguarde in Clevedon again if i get no joy at cardiff, they were great last time, just means wifey has to come with me in her car to bring me back, and i will have to promise shopping for points!! . ;

more to follow!!

Ub

 

[BlackC55]

Thanks for the info

Update:

Coming home from work just now and she boosted fine, a couple of times i had to back of the throttle and then kick down and it would boost fine, the same in sport mode,
first time it has behaved.

I am hoping it is the same tomorrow morning, either way I am off the merc cardiff tomorrow to speak to them as they were supposed to call me tuesday morning and never bothered.

Also I may pop to Avantguarde in Clevedon again if i get no joy at cardiff, they were great last time, just means wifey has to come with me in her car to bring me back, and i will have to promise shopping for points!! . ;

more to follow!!

Ub

It takes about 5 mind to re-set the adaptions. They can probably do it while you wait.

 

[unclebuck]

Update:

I think that I am probably going to put it back on the drive, take everything off again and also get the inlet manifolds off and check / clean them and upgrade the arms, nothing wrong wit hthe turbo at all.

got all the gaskets and new bolts for this, just replacing the turbo gaskets and bolts AGAIN!!

oh well.

UB

 

[TeddyRuxpin]

...but what did MB Cardiff say?

 

[toolman1954]

Hello,
I have been following this thread with some interest as my latest 05/06 211 with now 78,000 miles on it has been leaking oil for some time, according to the old MOT's, and this week, while I am home in Northampton, I bought a big bag full of gaskets and seals from Mercedes in Northampton ( very helpful in the parts dept ) with a view to doing the cooler seals.
Not only but also, since I bought the car in May, it has suffered with lack of boost and goes into limp mode if I try to toe it. Strangely there are no codes coming up for this, so I was hoping that stripping everything down my reveal something seized up as it had been standing for some long time. I did replace the turbo boost sensor, but stopped at the price of a batwing. !
Fortunately, I can still manage the journey up to Scotland as 80mph is just 2000 rpm and I can drop a gear using the Tiptronic.
So, for Ollie,............. please, I was wondering what the adaptions are and why they are needed to be reset.
When I get back up to Leven, my nearest dealer would be Edinburgh if I needed any reset of this kind.
Thanks.......... Steve.

 

[unclebuck]

...but what did MB Cardiff say?`

Hello,
I have been following this thread with some interest as my latest 05/06 211 with now 78,000 miles on it has been leaking oil for some time, according to the old MOT's, and this week, while I am home in Northampton, I bought a big bag full of gaskets and seals from Mercedes in Northampton ( very helpful in the parts dept ) with a view to doing the cooler seals.
Not only but also, since I bought the car in May, it has suffered with lack of boost and goes into limp mode if I try to toe it. Strangely there are no codes coming up for this, so I was hoping that stripping everything down my reveal something seized up as it had been standing for some long time. I did replace the turbo boost sensor, but stopped at the price of a batwing. !
Fortunately, I can still manage the journey up to Scotland as 80mph is just 2000 rpm and I can drop a gear using the Tiptronic.
So, for Ollie,............. please, I was wondering what the adaptions are and why they are needed to be reset.
When I get back up to Leven, my nearest dealer would be Edinburgh if I needed any reset of this kind.
Thanks.......... Steve.

re the bat wing get one now as this price is good:

Genuine Mercedes-Benz OM642 Engine Turbo Air Intake With Air Mass A642090823780 | eBay

Unsure on Suitability?. 100% Genuine Parts. Isle of man. Engine Oil. Engine Servicing. Engine Parts. Can't find what you are looking for?. Isle of White.

www.ebay.co.uk

this is for the om642 engine i dont know if this is the same as the one on yours however I am sure someone will let us know.

Tomorrow I am taking the throttle flap assembly off the front of the engine to check things over as my throttle seemed to stick today and the revs didnt drop when i took my foot off the pedal.

Hence my thinking that the manifolds are probably full of crud and they are randomly sticking and also causing the boost issue or it could be the throttle flap sticking or both.

Cardiff want the car for a diagnostic first before anything else is discussed, oh and by the way a new Merc Garret turbo is £2948.40 inc vat and a reman is £1556.40 in vat.

Spoke with my turbo suppliers and the guy who built mine, my turbo spec is exactly the same garret setup as the original one was they have everything on file relating to the correct setup for the numbering off the old turbo in relation to setting up the new one ( mine came with new fitted actuator and the turbo was setup on their machines prior to sending out) merc dont make turbos they are garrets just with a merc stamp on them.

I have everything here to do the manifolds, might as well get them off, cleaned up regardless of how much crud is in them and do the oil cooler seals as well i have a full set of new bolts for the oil cooler and new seals also a full set of new bolts for the inlet manifolds and a new coolant pipe to go from the drivers side inlet manifold to the radiator ( might as well change it also)

once this is all off i will need:

new turbo gaskets (again)
various mounting bolts for turbo (again)
new swirl flap motor link clips as i will probably break them taking them off ( again )
coolant ( obviously )
going to fit another new exhaust back pressure sensor

once all of that is done if all is good then great, if its still there then off to an independent for a full check.

I am so far down the rabbit hole now I might as well get to the bloody end of it!!

Hopefully a couple of pics tomorrow as long as it doesnt rain.

 

[W1ghty]

Hello,
I have been following this thread with some interest as my latest 05/06 211 with now 78,000 miles on it has been leaking oil for some time, according to the old MOT's, and this week, while I am home in Northampton, I bought a big bag full of gaskets and seals from Mercedes in Northampton ( very helpful in the parts dept ) with a view to doing the cooler seals.
Not only but also, since I bought the car in May, it has suffered with lack of boost and goes into limp mode if I try to toe it. Strangely there are no codes coming up for this, so I was hoping that stripping everything down my reveal something seized up as it had been standing for some long time. I did replace the turbo boost sensor, but stopped at the price of a batwing. !
Fortunately, I can still manage the journey up to Scotland as 80mph is just 2000 rpm and I can drop a gear using the Tiptronic.
So, for Ollie,............. please, I was wondering what the adaptions are and why they are needed to be reset.
When I get back up to Leven, my nearest dealer would be Edinburgh if I needed any reset of this kind.
Thanks.......... Steve.

You could go via Jay at Mercland , Nuneaton (MB specialist)

 

[toolman1954]

You could go via Jay at Mercland , Nuneaton (MB specialist)

Uncle B ......Apologies for using your post....I will leave a shilling in the box and create my own on this topic at some point in time.
W1ghty..... Good call, but Northampton to Leven is an 8 hour 400 miles journey. I am loaded up with stock at the back end, Jack, my dog, he has the centre section and I get the passenger seat for my P.C., Laptop, Bookwork, food, clothes and any other rubbish.
I try to leave at 5-00 am so stopping off at Nuneaton is just not possible.
What does annoy me, is that I probably did 50K in my old green 211 that had the IL6 and not a hic cup from the engine bar the Injector seals and EGR clogging up at some point.
This one has been trouble since day one, despite its low mileage.......Hopefullly one day it will be sorted.
Steve.

 

[unclebuck]

update:

Took the front throttle flap assembly off as i wanted to check it over and change out all the seals finally.

Only took me around 30 mins to get it all off and start breaking it down, there was a little oil in there and the egr pipe had some coking inside, not much but enough to warrant a good clean.

The throttle flap was a little contaminated so this had a good spray and clean also, whilst doing this it decided to rain which really pissed me off so rain stopped play for a while.Started putting things back together with new seals and cleaning up the bolts before re tourquing things down.


pics as usual.

new egr pipe seal : A642 141 00 80

cleaned up the three M6x16mm hexolobular bolts and refitted teh egr pipe and torqued down

Also cleaned up the IAT intake air temp sensor with a really fine paint brush ( modellers brush ) and some cleaner.

Cleaned up the throttle flap little bit of surface coating but nothing much.

 

[unclebuck]

Update 2 :

Now the biggie!!

I decided to take a look at the exhaust heat exchanger that runs to the front of the engine that the egr etc connects to.

Shined a torch in there and this is what I found... almost blocked with crud and coked up.

Logic states that the Inlet manifolds must be in a shit state so I have no option but to take it all off and clean it all out, its going to be busy next week!!

Pics not for the faint hearted!! lol.