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Latest on my W202 C230K aka ''Rough Rough''

24. Fit new plugs, NGK BKR7E's - received
25. Fit direct mount fuel pressure gauge - received.
26. Find fuel rail adaptor to suit above - ordered.

Photo of very neat 1.5in/38mm F/P gauge.
 
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22. Replace both front lower ball joints. Groan after reversing and then moving forward on lock. Not good!

Ordered from eBay.de, these are what's know by Meyle as a Heavy Duty version. They also supply H/D upper & lower front wishbones, I think they are specifically for the C36 but should do nicely on any W202.

MEYLE - Autoersatzteile für den freien Teilehandel - Meyle

And new one to the infamous list is:

#30. MAF clamp, 4.6v Zener diode. - ordered.
 
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At last the fuel pressure gauge is fitted. Not straightforward when it came to fitting it unlike other cars thanks in part to the canted location of the Schrader valve port. Anyway, it was something I wanted to do even if it's not really significant.
 
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Another list! :D

After a practical evaluation of what needs to done and sticking with preventive maintenance as a priority along with resolving my boost loss issue I've drawn up a revised list again. But this time it's more focused and less time demanding, just hope I've covered everything. When all of below is completed then I'll progress to part two.

Part 1.

1. Fit Plugs (3rd different set) + plug cover bolt washers.
2. Adjust boot Lock striker.
3. Fit front Ball joints.
4. Strip, deglaze and clean Brakes.
5. Clamp MAF + relocate to T/B.
6. Check Throttle cable adjustment.
7. Change S/C oil. (again)
8. Permanently fit Boost gauge and wire up.
9. Permanently fit Fuel pressure gauge.
10. Fit Sill blanking cover.
11. Fit Boot lid S/s bolts.
12. Glue 38 pin port cover seal.
13. Polish windscreen and lub Wiper mechanism (again).
14. Fit R/cover gasket & plug seals.
15. Paint R/cover.
16. Check Cam position sensor
17. Check Cam magnet.
18. Check Breather hoses.
19. Change PAS fluid. (again)
20. Pressure test boost hoses and I.C..
21. Fit Throttle Body seal.
22. Replace Key batteries. - order.
23. Engine Oil & filter change (3rd time in 12k miles) - order.
24. Remove front & rear bumpers for bodywork inspection.
25. Engine Coolant flush + change + Thermostat. - order.
 
Nothing exciting or of any real interest, just updating.

I've made some progress over the last few months but it's all stop start, read slow. Thus, keeping a thread on what's what and more importantly what's not been done seems even more worthwhile than ever.

My 4.7v Zener diode arrived a few weeks ago, so that's soldered in now on the MAF loom. Next thing to do there is give the old girl a drive, 200 plus miles and also check max voltage @ the MAF output. Hopefully it's below 4.8v as against the normal 4.99v. I also changed the MAF housing for a spare one I had as it was getting a little loose due to constant removal and refitting.

I purchased a spare used S/C clutch pulley and Bypass valve from a fellow member, handy to have just in case. Plus I also got a job lot of parts including some basic service items and a Bosch o2 sensor from another member, again at a bargain price. And since I was in the purchasing mood a new set of Eibach Pro-Kit springs (E2545-140) found there way to me. For just over a hundred quid/c.€148 from Germany including delivery, at that price it would have been rude not too.

While I was checking the condition of the 'go faster' K&N air filter I noticed the sponge around the inlet air baffle within the air box was breaking up. What a good excuse to take the rest of it out along with the baffle! That's another 5bhp gain...



Part 1.

1. Fit Plugs (3rd different set) + plug cover bolt washers. Done
2. Adjust boot Lock striker. Done
3. Fit front Ball joints. Done
4. Strip, deglaze and clean Brakes. Half way there
5. Clamp MAF Done+ relocate to T/B.
6. Check Throttle cable adjustment. Done
7. Change S/C oil. (again) Done
8. Permanently fit Boost gauge and wire up. Done
9. Permanently fit Fuel pressure gauge. Done
10. Fit Sill blanking cover.Done
11. Fit Boot lid S/s bolts. Done
12. Glue 38 pin port cover seal. Done
13. Polish windscreen and lub Wiper mechanism (again). Done
14. Fit R/cover gasket & plug seals.
15. Paint R/cover.
16. Check Cam position sensor
17. Check Cam magnet.
18. Check Breather hoses. Done
19. Change PAS fluid. (again)
20. Pressure test boost hoses and I.C..
21. Fit Throttle Body seal. Done
22. Replace Key batteries. - order.
23. Engine Oil & filter change (3rd time in 12k miles) - order. Done
24. Remove front & rear bumpers for bodywork inspection. In progress
25. Engine Coolant flush + change + Thermostat. - order.

New:
26. Replace Intercooler rubber mounts x 3 on N/s - order.
27. Replace missing boot trim clip - order.
 
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Current state of play as of today.

Part 1.

4. Strip, deglaze and clean Brakes. Half way there
5. Relocate to T/B.

14. Fit R/cover gasket & plug seals.
15. Paint R/cover.
16. Check Cam position sensor
17. Check Cam magnet.

20. Pressure test boost hoses and I.C..

22. Replace Key batteries. - order.

24. Remove front & rear bumpers for bodywork inspection. In progress
25. Engine Coolant flush + change + Thermostat. - order.
26. Replace Intercooler rubber mounts x 3 on N/s - order.
27. Replace missing boot trim clip - order.
28. Fit Eibach springs.
 
Moved to projects :)
 
Update.

After a full stripdown of the brakes I found that new front discs are required very soon plus pads. The front backing plates were rather rusty but cleaned these up, treated them and then painted. I will replace these when fitting the new discs. Rear discs are o.k. and pads are just about half worn. The shoes are excellent which I cleaned up, refitted a loose spring and lubricated the adjusters. Found no play in either front or rear wheel bearings. I also replaced both front ball joints, very easy to access with the discs and backing plates removed. The old joints had some wear but nothing that seems excessive but better to be safe than sorry as I did hear a noise from the front when reversing on lock.

I'm still cleaning, treating and painting some of the lower body/chassis rails behind the front and rear bumpers. Nothing really serious found but some superficial rust at the rear o/s 1/4 panel air vent behind the bumper. Above the exhaust back box too which I removed to gain access. I also found both front bumper mount plates below the front wings corroded. Again these were removed and hit with the flapper disc, cleaned, treated and painted along with repairing two snapped mounting bolts. Won't go into any more detail as I forgot to take photos which would have said a thousand words.


Part 1.

4. Strip, deglaze and clean Brakes. Done
5. Relocate to T/B.

14. Fit R/cover gasket & plug seals.
15. Paint R/cover.
16. Check Cam position sensor
17. Check Cam magnet.

20. Pressure test boost hoses and I.C..

22. Replace Key batteries. - order.

24. Remove front & rear bumpers for bodywork inspection. Still in progress
25. Engine Coolant flush + change + Thermostat. - order.
26. Replace Intercooler rubber mounts x 3 on N/s Done
27. Replace missing boot trim clip Done
28. Fit Eibach springs.
29. Replace rusty exhaust downpipe nuts & bolts x 2, packing ring and the flange nuts & bolts x 3 just after the cat.
 
A few photos.

Front bumper carried mounting which was rusted.
Rear bumper carrier location point N/s.
Rear bumper carrier location poin O/s and air vent aperture.
 
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And another few (disregard the first photo).

Here is the S/c outlet pipe that the MAF connects to. The pipe/housing is mounted to the N/S chassis rail by three rubber mounts that are screwed into the rail and bolted to the housing. All of these were broken which I suspect was due to failing engine mounts and age.
 
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Update. Still a bit to do but sadly the holidays are drawing to a close. I ordered a spring compressor specific for M-B springs hopefully it's acceptable quality but I have my reservations as it was advertised on eBay by what looked a German supplier but in actual fact it's Chinese. That will teach me to read the complete advert right down to the very last details first before ordering. Anyway for sixty quid delivered it's not the end of the world if it's not up to much abuse.

Ideally I'll need new front discs and pads and I think I'll order stainless steel M6 bolts for the rocker cover when I get around to painting it. I'll also fit S/S bolts to the front panel, bonnet lock receiver and may be the wing bolts too.

Part 1.

5. Relocate MAF closer to T/B.

14. Fit R/cover gasket & plug seals.
15. Paint R/cover.
16. Check Cam position sensor
17. Check Cam magnet. Done


20. Pressure test boost hoses and I.C..

22. Replace Key batteries. - order.

24. Remove front & rear bumpers for bodywork inspection. Still in progress
25. Engine Coolant flush + change + Thermostat. - order.

28. Fit Eibach springs.
29. Spring compressor - ordered.
30. Replace rusty exhaust downpipe nuts & bolts x 2, packing ring and the flange nuts & bolts x 3 just after the cat.
 
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I have that cheap tool too. It does the job just fine for us amateurs. I would question how long it would last in a workshop being used frequently but ultimately it's a fairly simple piece of kit.
 
mattc said:
I have that cheap tool too. It does the job just fine for us amateurs. I would question how long it would last in a workshop being used frequently but ultimately it's a fairly simple piece of kit.
Click to expand...


Yep, I'd be of a similar mind to you. It's deffo not workshop quality, just hoping it will serve me o.k. as I'll possibly only use it a half dozen times. Fingers crossed.
 
I read somewhere before that to avoid copyright infringement, copies have to have at least one thing removed from the design and it was some safety feature. Found it on another forum, can't remember where.

Worth keeping an eye on ebay.de if you're after a genuine Klann version of this compressor as they do sometimes come up. Mine has been used once or twice before so virtually new and was less than 1/2 the price of a new set.
 
John Jones Jr said:
Yep, I'd be of a similar mind to you. It's deffo not workshop quality, just hoping it will serve me o.k. as I'll possibly only use it a half dozen times. Fingers crossed.
Click to expand...

I haven't managed to kill it yet, 3 years, 50+ springs.:thumb:
 
carat 3.6 said:
I haven't managed to kill it yet, 3 years, 50+ springs.:thumb:
Click to expand...

Good to hear Simon. I hate having crap/rubbish tools but on the other hand I can't justify paying top dollar for a spring compressor as it's something I'll rarely use.
 
Thanks for the offer, really appreciate that and nice to know. :thumb:
 
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