W211 2007 E320 CDI Jerky / Power Loss Problems

[Lord_A]

Hi,

I could really use some advise with my car please...

I purchased an E320 CDI 2007 V6 facelift model just over a year ago with full MBSH & 42500 on the clock. Car needed a service 'E' at the time and was a couple of weeks overdue so I only drove the car very gently for 300 miles or so and booked it in with my local Mercedes dealership.

Part of the work involved was an ATF change and they also replaced a leaking oil o-ring seal on one of the turbo pipes.

A couple of weeks from having had the car serviced I started experiencing very jerky revs when in 2nd, 3rd, or 4th gear. This would only happen when I accelerated quite hard or when using the kickdown function on the accelerator. This would happen very intermittently, with the engine & gearbox fully warmed up or from cold, and in both C & S modes on the gearbox.

I would on occasion also experience a loss of power from the car, and it would go into limp home mode until I pulled over and switched it off and back on again - something which cured the jerkiness 99% until the next day / week / etc.

As it was very intermittent I didn't do anything about it, and it was happening so rarely that I just left it until the next scheduled annual service (a 'C' service this time). I took the car back to the dealership & asked them to investigate the problem.

They reported the following fault codes:
2510-001 - Check component Y77/1 (Boost pressure regulator). Positioner signals fault. (STORED)

2616-002 - Check component B60 (Exhaust back pressure sensor). Control variation - Exhaust backpressure is too high. (STORED)
2644-011 - Check component B2/6 (Left hot film mass air flow sensor). Value is above limit. (Current and stored)


They recommended replacing the MAF & O2 sensors, as well as a clean of the air line. I authorised the work even though this was, to me at least, a massive cost of £754.


Just 2 days after collecting the car the problems re-appeared, I took the car back and they replaced the air filter, boost pressure sensor & reset the adaptations (all FOC) and were convinced this would now solve the problem. Interesting to note here is that they told me they found no more error codes on the car before carrying out this work.


The car had the same problems again a day after I collected it so I took it to an indie who scanned the car and found the same three error codes listed above.


I have now taken the car back to Mercedes who have had it for yet another week and have just received a phone call telling me that my turbo unit needs replacing to cure the loss of power problem (due to error code 2510-001) but they do not know what is causing the car to be jerky...they suspect it might be the exhaust manifolds but would like to replace the turbo unit first.


I have searched these forums (and others) and can see that there have been a few W211 series owners who have had similar problems.


Can anyone help me with these codes because I do not have £1800 to spend on replacing the turbo, nor a further £1200 to replace the manifolds, especially when Mercedes cannot tell me that doing either will definitely fix the problem.


Posts I have found with owners having similar problems are here:
01; 02; 03; 04; 05

 

[BlackC55]

This will be very likely a turbo issue.

Seen it a few times and is quite common.

 

[Lord_A]

Thanks for the reply though it's really not what I wanted to read.

Is it that common for a low mileage Mercedes to have such a failure on the turbo? This is the first expensive car I have owned after driving around in 'bangers' and really expected better reliability.

I don't have the money to replace it now so I am just going to take the car back and will sort it out once I have saved enough money.

 

[sinewave]

Olly is spot on the money!

My Car had all the same symptoms you describe including the same codes.

Your mileage is low TBH as mine was on 94K when it went failed.

The Turbo it'self is probably mechanicaly fine, it's actually the 'electrics pack' on the side of the Turbo which is breaking down under load (hard acceleration) but Mercedes do not supply this as a separate item so a New Turbo it is!

An MB dealer will rob you around 1.5-2K for this work so I suggest you find a good Indy and buy a new Garrat Turbo (same as MB use OEM) from someone like this instead who from memory charge around £845 for a new unit.

Tait Euroturbos | Turbochargers for BMW, Toyota, Subaru

 

[Lord_A]

Thanks for the advice on the turbo unit, I have found a Garrett turbo for under £600 brand new delivered. I'll contact my indie and check how much labour they would charge.

Just out of interest did replacing the turbo resolve the jerkiness on your car as well? I ask because the dealer told me they aren't sure what is causing that but they suspect the manifolds might need replacing as well.

 

[sinewave]

Yes, fixed it and runs well now.

Mine was done under a Warranty Direct policy, labour was £180, not that I paid, but just so you have an idea.

 

[Lord_A]

Thanks, I didn't take out extended warranty, wish I had now!

 

[Dj Sky]

Hello,
@ Lord_A, did you resolved the problem? If yes, how?
I have the same issue with my car, E 320 cdi v6, 2006 but in my case, it happens very rarely. I have few months and 10.000-15000 km until the problem reapeears.
Star Diag reported me the following fault code,but only one, like yours...
2616-002 Check component B60(Exhaust back pressure sensor). Control variation, Exhaust backpressure is too high. Error stored, not current.

 

[billy21]

I'm another one who's interested in @Lord_A's car. Like @DJ_Sky I've had these problems very intermitently in the past year and had my car (W211 E320 cdi 2009) checked on star. The 2616-002 error showed up and as a result i had the back pressure sensor replaced. However I still sometimes get the very jerky acceleration problems discussed earlier in this thread. My mechanic is stumped as he doesn't think it's necessarily a turbo problem (no other codes are coming up).

 

[joecash]

its very important to find a competent mercedes mechanic - its worth travelling over 100 miles to see one in my opinion - if your mechanic isnt competent it could literally cost you thousands for his/her trial and error excuses - just my view

 

[Dj Sky]

Thursday I will remove the actuator from the turbo to open the case and check the mechanical parts inside.I understand that there are some gears which can escape from pozition should have it in a speedy accelerate so the engine haven't enough air, or has too much.
There is no one to be replaced the part of turbo actuator or all turbo parts and the problem disappear? In Romania there are still a few identical cases on Clubmercedes.ro with a E, R class and CLS 320 CDI.
I want to clean the EGR Valve and the Back Pressure Sensor.
I will come back with details of operation, what problems i observe and i hope to can take some pictures to share with you.
Saturday is a week since never caused a problem and do not know how to eliminate the cause if it occurs rarely and without any basis.

 

[BlackC55]

Some of the actuators 'appear' ok but are still faulty.

 

[billy21]

Just found out this morning that I need a new turbo - Just under £1500 for a Garrett part fitted - ouch!
It would seem if you have this particular problem - the violent jerkiness when accelerating - then it is almost certainly time for a new turbo. Will confirm if it fixes the problem

 

[Dj Sky]

Hello, @ Billy21 you have new informations after replacing the turbo?
I tried to remove the EGR valve, but I can not ... I could just remove the screws, but EGR still would not move ...
I removed the rear pressure sensor, he had a large amount of smoke soot from the sensor plug hole entirely. I cleaned it with a brush and I cleaned the sensor with brake discs cleaning spray.
Since then I have had symptoms in second day after i removed the back pressure sensor and now i have 2000-3000 km since the problem doesn't appear at all. Every time, my car do this 10-15 times and the problem dissapear from 6-12 months. I don't know what to replace

 

[billy21]

After 3 weeks and several long runs the problem has not returned. I have also noticed that the car pulls with a lot more vigour under all conditions - it really feels like a new car! I spoke to my mechanic who did quite a bit of research on this problem and it seems like a replacement turbo is the only answer when your car has the symptoms described above.

 

[rascalmaster]

turbo knackered :-(

causes erratic readings in sensors and resulting gear changes .

had mine replaced under warranty soon after i got it.

also need to make sure no oil is dripping onto the port inlet motor casing located under the turbo/ air inlet connection. dodgy sealing here will result in oil leaks and any going into the gubbins will knacker that as well!

 

[Dj Sky]

After 3 weeks and several long runs the problem has not returned. I have also noticed that the car pulls with a lot more vigour under all conditions - it really feels like a new car! I spoke to my mechanic who did quite a bit of research on this problem and it seems like a replacement turbo is the only answer when your car has the symptoms described above.

Thank you very much for your opinion.
My car make me to forgot about this problem, are almost 3 months and 5000 km, from last time when i haved that problem. I hope to take some time until it appear again.
i'm happy for you because you resolved the problem.
If you see this post, please notice us about that problem, i hope to not appear again, and your car runs "like new ".

 

[Hss]

Hello all, I'm new to this forum so Im not too sure as to where to post my query, I too have had the same problems relating to my car its the w211 E320 CDi V6 with the OM642 engine, my car too developed the same symptoms such as the jerkiness when accelerating. The car would then loose all power and divert to limp mode until switched off and restarted. The problem got worse and the car now feels like the turbo isn't working properly

i got the car hooked onto Star by an Indy and found the codes 2510 001 - Check component Y77/1 with points to the electronic actuator on the turbo, the Indy performed tests on the actuator and it passed. But the problem presented it self the next day As a precaution I had the actuator replaced by a reputable company with a recon unit, yet the problem still exists.

I have also checked the turbo vane lever for jamming by disconnecting the lever and moving it up and down, the lever moves effortlessly with no resistance whatsoever. The exhaust back pressure sensor and EGR valve have also been cleaned along side the two MAFs yet the problem still exists

One thing i did notice was that with the lever dis connected I had started the car and the lever did go up and down as normal but when pressing the accelerator pedal the actuator arm did not seen to move much up until 2500 rpm which in my opinion doesn't seem right, the car then makes a sucking sound if the revs are held at 3000 rpm

I apologise for the long post as I'm new to this forum and completely stumped with this problem

 

[billy21]

Hello Hss,

from what you are describing it sounds like the turbo is in the way out - or probably the actuator is on the way out. They can't be repaired so the only alternative is a new turbo. I also had confusing codes coming up on the STaR machine but after a bit of research it seems this is a not too uncommon problem with this engine. I had mine replaced at a good Mercedes indy and it came in at about £1400. The car has been fine ever since.

good luck.

 

[Hss]

Hello Billy, thanks for taking the time to reply, i had initially thought that the replacement actuator which I had bought maybe faulty so I had it sent off and a replacement actuator was fitted but the symptoms still persist, how much was the new complete turbo inc the actuator?


The car just doesn't feel responsive as it was
when i purchased it back in September with 110,000 miles i can hear the turbo spinning with no whining noise etc however i suspect the problem lies elsewhere as the electronic actuator doesn't seem to move as it should and the car doesn't feel powerful enough untill revved up to 2500 3000 rpm feels like the turbo isn't working properly up until 2000 rpm, i also had the inlet port shut off motor bypassed but that did not make any difference to the power/ jerkiness

I had a full service carried out by a mercedes specialist who reported no faults or codes on the car, its now done 113,000 doesn't have any other problem