intake manifolds, oil cooler seals

[TeddyRuxpin]

Oooh you've got that all nice and shiny! That must of taken a lot of work...

I've opened mine up twice, including taking the black plastic off last time. I didn't notice mine binding and was surprised at the condition and how smooth it felt @ 160k. It didn't solve my juddering on light acceleration, didn't notice any change at all (but then maybe it didn't have a problem in the first place). Now I'm paranoid that I didn't check it properly!!!

Have you put it back in the car and noticed any difference? What's are the current/actual problems with the car at the moment?

 

[unclebuck]

Oooh you've got that all nice and shiny! That must of taken a lot of work...

I've opened mine up twice, including taking the black plastic off last time. I didn't notice mine binding and was surprised at the condition and how smooth it felt @ 160k. It didn't solve my juddering on light acceleration, didn't notice any change at all (but then maybe it didn't have a problem in the first place). Now I'm paranoid that I didn't check it properly!!!

Have you put it back in the car and noticed any difference? What's are the current/actual problems with the car at the moment?

Still getting that damn P0299 underboost however, tonight on the way home about half way it went into limp mode, same code nothing else well... I fkn had enough, cleared the code, put it in sport and fookin wellied it down the road. It did not lose boost once, it did not go into limp mode, put it back in comfort and the same it boosted perfectly all the way home.

I really think its the damn egr valve sticking randomly thats the cause behind everything, the fact it kept binding for me last night on the desk I cannot see it being anything else.

I was getting a basic cheap egr but now I am going to get a pierberg egr valve as its a good quality one, I bet a cat's nipple that will cure it, she is still going into avantguarde for a diagnosis, check everything over and adaptations along with ecu software check.

Gotta say though, the boost in sport mode, when it kicked in, the grin was LARGE!!!!!!!!!!!!!!!!!!!!!!!!

 

[W1ghty]

Still getting that damn P0299 underboost however, tonight on the way home about half way it went into limp mode, same code nothing else well... I fkn had enough, cleared the code, put it in sport and fookin wellied it down the road. It did not lose boost once, it did not go into limp mode, put it back in comfort and the same it boosted perfectly all the way home.

I really think its the damn egr valve sticking randomly thats the cause behind everything, the fact it kept binding for me last night on the desk I cannot see it being anything else.

I was getting a basic cheap egr but now I am going to get a pierberg egr valve as its a good quality one, I bet a cat's nipple that will cure it, she is still going into avantguarde for a diagnosis, check everything over and adaptations along with ecu software check.

Gotta say though, the boost in sport mode, when it kicked in, the grin was LARGE!!!!!!!!!!!!!!!!!!!!!!!!

Drive it like you stole it buddy

 

[unclebuck]

Update:

Went back out to the car this evening and took the EGR valve back off again to check it, it was absolutely black with soot, both sides of the valve seal.

This time i removed the split pin that holds the bearing in place, this allowed me to move the swing arm over further and take the bearing out to check.

the bearing was fine the race was smooth no issues there, the swing arm moved smoothly too however, i noticed that there was a tiny bit of play side to side in all directions of the valve stem through the mount, also it felt gritty moving it up and down. I sprayed some cleaner in and move the valve up and down many times and wiped everything back down again.

Once re-assembled the valve still stuck a few times again as the valve also rotates slightly causing the edges to rub

I have read that if there is a lot of soot on the egr valve, and the rear of the turbo ( turbine ) and the exhaust tips that this is a sign of the egr valve sticking, also it can stick momentarily and not throw codes up to the ecm.

Still waiting for the new egr to arrive, once its here I will fit it and take the car out again if it is still there then it will have to wait until it goes into Avantguarde in a couple of weeks time.

 

[MrGreedy]

Good thing to find out though. I don't know what level of soot is normal, but this and a new EGR and into Avantguard should get you well on the way to recovery.

P.S. glad you are going to AG and not to a Merc dealer for their 'help'

 

[TeddyRuxpin]

You guys might enjoy this video... starts properly at about 3 mins.. grab a cup of tea and enjoy... and make sure you change your oil regularly eh?!

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[OneForTheRoad]

You guys might enjoy this video... starts properly at about 3 mins.. grab a cup of tea and enjoy... and make sure you change your oil regularly eh?!

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Great video. Reminded me of a vauxhall corsa i once bought for the Mrs. I took out the sump bung and this tar like blobby substance came slowly southbound. Took a few engine cleans mixed with diesel to get it sorted. The seller informed me its wanted for nothing . !!!

 

[unclebuck]

Update:

Last night i pulled the egr again, it was tasking my mind constantly. I took it apart again and this time i got my dremel with a small conical griner bit and smoothed the edges of the U channel and rounded them slightly, this meant there were no edges for it to catch on, I also smoothed and rounded the arm slightly. Once done all was cleaned out of the fine metal dust and bits, then blasted clean with air. The arm, bearing and U channel were then liberally coated with a high temp grease and it was re-assembled.

Took the car out today, and it has been non stop constant boost in comfort and sport mode.

So other than the egr valve i found a good replacement intercooler online and I have ordered that now also, as everything has never been looked over properly previous to me having the car I have decided to just change that out also.

So a how to on that as soon as it arrives, also i will take the old EGR valve completely part once the new one has been fitted to see whats inside the valve stem shaft on the casting and how much crud is in there.

Apart from that gave the engine bay a little clean up today in the sunshine.

 

[TeddyRuxpin]

So, no codes after dremeling the EGR?

Is the intercooler 'uprated' in any way, or OEM spec?

Look forward to your intercooler 'guide'!

 

[unclebuck]

So, no codes after dremeling the EGR?

Is the intercooler 'uprated' in any way, or OEM spec?

Look forward to your intercooler 'guide'!

Nope no code however, it did this the other week coming home from work, it went into limp once then boosted on both settings all the way home.

Will see how it behaves on the journey to work tomorrow, knowing my luck it will be back to normal.

The intercooler is just a Merc standard intercooler nothing fancy that dosen't need to be there but i am going to change it out anyway.

The injectors are going to be coming out shortly also, i dare say they are due a service/clean up. There is a guy locally who will come to your home and take them out for you and do the seats prior to refitting them. He is a specialist who has been doing them for years and they probably need doing by now.

Also going to replace the lower ball joint on the fronts again as I have a set here spare and do the front brakes and discs before the mot in january.

I have found a nice pop-up gazebo to go over the car when i am working on it it the cold wet weeks to come!

 

[MrGreedy]

I'd be interested where you get the intercooler also, as when I was replacing the air con condenser the other week, I noticed mine has seen better days. Mostly full to the brim of road detritus and dust, so airflow through that won't be very good at all. It looked visually blocked and I couldn't make too much difference vacuuming or blowing it to try and clear it.

 

[unclebuck]

Getting it from euro car parts.

 

[BlackC55]

If its in limp mode there will be a code. Some code readers out there will not pull all the codes. Only a Star (Xentry) will. It may not be going into limp mode either. It could have a lack of power thats not bad enough to be picked up by the engine control unit.

 

[unclebuck]

If its in limp mode there will be a code. Some code readers out there will not pull all the codes. Only a Star (Xentry) will. It may not be going into limp mode either. It could have a lack of power thats not bad enough to be picked up by the engine control unit.

The other issue may be the throttle body as i mentioned in another thread ( should have just put it here really) I know when you turn the engine off it settles the flap back to a start position etc, but mine is doing this between 5 and 7 times after i turn the engine off and its loud, I am going to try and record it today. I really want this bloody thing resolved!! its wierd as one day it will boost fine and no issue then next day limp mode. i cant win for trying!!

Still its going to Avantguarde soon, better minds than mine with more experience and the right tools.

 

[unclebuck]

Update:

MEEP MEEP........................................

 

[W1ghty]

Update:

MEEP MEEP........................................

The Roadrunner ?

 

[Nicebutdim]

The Roadrunner ?

I think the om642 has finally pushed him over the edge.

 

[unclebuck]

 

[unclebuck]

Update:

Last night I found a random post on a forum about P0299 being linked to a flaky exhaust back pressure sensor that was giving way off pressure readings. hope the admins don't mind me sharing the thread link

Overboost/Underboost problem solved - MBWorld.org Forums

M-Class (W166) - Overboost/Underboost problem solved - This post is only meant to help those in the future who might find the same problem related to an Exhaust Pressure Sensor and turbo overboost/underboost, as I found little on this specific problem for this specific engine. Got a check engine...

mbworld.org

I remembered that when I had the car checked before the star system showed something about my back pressure sensor as well below the turbo info.
which I never followed up as i was just concentrating on finding a new turbo for the car as the impellar blades were badly damaged and it was sticking on the vvt vanes.

The Star info:


Last night while still looking on the net for info relating to anything to do with the P0299 issues I came across a random post on another forum in which the OP detailed his issues with having the P0299 error and limp mode and how when he did live readings his pressure was all over the place.

I replaced my back pressure sensor when i first got the car along with other sensors around the car which were erroring and needed replacing, the bacl pressure sensor was not erroring but i replaced it at the time as a precaution.

The sensor was bought from Autodoc at the time and it was a Ridex sensor, not a manufacturer I knew of but I did not think to get one from Mercedes spares at the time.

So after reading the thread post I remembered I still had the original sensor in my parts tray, I pulled it out, sprayed some cleaner into the sensor barrel and cleaned it all out of soot until it was spotless.

It was 10:45pm and I still went out last night and replaced the Ridex for the original sensor.

What happened to day on the way to work.......

It was like a totally different car, the kick in was instant with a light squeeze of the accelerator pedal and boost was stable and correct, it just drove beautifully.
I spent all day in work impatiently wating to get back in the car and drive home, I have to say the drive home was just as glorious!!!! I opened it up in sport and the car just kept going, no limp mode nothing just pure boosting joy!!

So it looks like the issue was the crappy non Mercedes Exhaust Back Pressure Sensor that I got from Autodoc ( never again )

I am going to order a brand new genuine sensor anyway along with spare new crush washer seals and then keep the old one spare.

Still fitting a new intercooler and having the injectors pulled and then i will strip them and service them then have the seats cleaned and refitted.

It's been a long road and the solution was there all along and I am glad i persisted and found it.

The main thing i think is everything I have learned working on the car, in the new year the in-out ports on the valves are getting walnut blasted as I couldn't clean them when I had the manifolds off.

Just get a few last things done and thats it, this weekend fit all the new brake pads and discs that have been waiting to be fitted and spend sunday giving it a well deserved clean.

I wanted to drive home and make sure it didn't go into limp mode before I posted hence the teaser posts

Really glad to be able to update you all on this good news.

Thanks for all the support and patience

UB

 

[MrGreedy]

I take the approach that anything electronic related to the engine gets replaced with either Merc parts or OEM where is van be identified. So Bosch for loads of sensors and Pierburg for motors often.

Glad this is hopefully over. You must be chuffed!