w211 om648

[cristispot]

Sorry, this is going to be a long text

I had an attempt to replace the copper washers because one of my injectors was leaking( common issue on this engine as you well know). The extractor tool that I have used was a bit too large and didn't fit properly under the injector and ended up chipping the fragile rocker cover. Eventually got the injectors out, cleaned them properly, cleaned the seats and all ready to go.
Took the old rocker cover out so i could replace it with another one, bought new seals, new bolts etc but i still had a problem finding the piece of aluminium from the broken rocker cover. I couldn't find it so I bought an inspection camera to look down in the engine, where the timing chain is, and eventually found it at the bottom of the timing chain( past the tensioners, looks like it sits on a cog).

I saw no way to pick it up from there, as I couldn't use a magnet or grabbing tool because the space is limited, so I have decided to push the piece of metal using the camera so it falls in the sump. Plan was to jack the car up, remove the oil, remove the sump, get rid of the piece of metal and put it all back together. When I tried to push it with the camera, I ended up getting the camera stuck between the chain and engine block. I have tried all sorts of ways to unblock it but it just won't come out, it's royally stuck. Now I have an inspection camera and a piece of aluminium metal stuck in the timing chain( great!). I saw there is a top cover where you can remove to have a better look at the timing chain, so i took the high pressure pump out and then gently loosen up the 6 bolts that holds the timing cover( not removed it completely because it looks like there is a plastic guide for timing chain that sits between cylinder head and the cover, so i was afraid i will mess up the timing chain, i don't have any locking tool kit for this).

I am based in Eastleigh, so i was wondering if anyone can recommend a mobile MB specialist that can come and have a look. Car is in the driveway now and id rather have it sorted there than recover it to a garage.

Thank you

 

[BlackC55]

I am local to you. I dont know of any MB mobile specialists in our area.

MBS Southampton is probably the nearest decent garage to you, Or myself of course.

 

[cristispot]

thank you. i know about you, and you were the first that came in my mind but i was hoping to find someone who can give it a go on my driveway rather than going down the route of recovering it and taking to the garage.

 

[mersum1es]

Sorry to hear you 'simple' problem to escalate... but usually they do BTW, magnet would have been useless... its aluminium anyway...

Those chinese puller system forks usually needs some grinder... their material is not as good as original MB tool so they have increased thickness...

 

[cristispot]

yes, i had to grind a lot until i got to the right dimension but it was too late at that stage as the damage was already done, and from there things escalated.

if the tool would have been ok from the beginning, i wouldn't have gotten in this situation.

i guess we learn from mistakes.

PS: yes, i know, magnet would have been useless for aluminium

 

[cristispot]

I am local to you. I dont know of any MB mobile specialists in our area.

MBS Southampton is probably the nearest decent garage to you, Or myself of course.

can you please send me a PM? thank you

 

[BlackC55]

I cant as you dont have enough posts. you can email me on info@prestigecarservice.co.uk

 

[McEwanClassics]

Sorry, this is going to be a long text

I had an attempt to replace the copper washers because one of my injectors was leaking( common issue on this engine as you well know). The extractor tool that I have used was a bit too large and didn't fit properly under the injector and ended up chipping the fragile rocker cover. Eventually got the injectors out, cleaned them properly, cleaned the seats and all ready to go.
Took the old rocker cover out so i could replace it with another one, bought new seals, new bolts etc but i still had a problem finding the piece of aluminium from the broken rocker cover. I couldn't find it so I bought an inspection camera to look down in the engine, where the timing chain is, and eventually found it at the bottom of the timing chain( past the tensioners, looks like it sits on a cog).

I saw no way to pick it up from there, as I couldn't use a magnet or grabbing tool because the space is limited, so I have decided to push the piece of metal using the camera so it falls in the sump. Plan was to jack the car up, remove the oil, remove the sump, get rid of the piece of metal and put it all back together. When I tried to push it with the camera, I ended up getting the camera stuck between the chain and engine block. I have tried all sorts of ways to unblock it but it just won't come out, it's royally stuck. Now I have an inspection camera and a piece of aluminium metal stuck in the timing chain( great!). I saw there is a top cover where you can remove to have a better look at the timing chain, so i took the high pressure pump out and then gently loosen up the 6 bolts that holds the timing cover( not removed it completely because it looks like there is a plastic guide for timing chain that sits between cylinder head and the cover, so i was afraid i will mess up the timing chain, i don't have any locking tool kit for this).

I am based in Eastleigh, so i was wondering if anyone can recommend a mobile MB specialist that can come and have a look. Car is in the driveway now and id rather have it sorted there than recover it to a garage.

Thank you

Cristispot, It seems we may be living a paralell life here. I have the same problem on my 2005 e320 cdi. Exactly the same issue with the cam cover ( made a good job of breaking it but all pieces found bar one) and yes that small piece of cam cover sneeks off down the cam chain gallery! . Ive removed the front inspection cover and bought an endoscope to look down (not got mine stuck yet though). Did you have any look with sorting yours?

 

[cristispot]

Cristispot, It seems we may be living a paralell life here. I have the same problem on my 2005 e320 cdi. Exactly the same issue with the cam cover ( made a good job of breaking it but all pieces found bar one) and yes that small piece of cam cover sneeks off down the cam chain gallery! . Ive removed the front inspection cover and bought an endoscope to look down (not got mine stuck yet though). Did you have any look with sorting yours?

hello, sorry to hear you're going through the same problem like i am.

didn't have much luck, i am waiting for @BlackC55 to work his magic in getting it repaired

what front inspection cover are you referring to? you mean the one behind the high pressure pump? did you get that out completely? i was afraid to remove mine as it looked like is holding a timing chain guide in place(i might be wrong though).

do you have any pics so i can see how it looks like behind the inspection cover?

 

[McEwanClassics]

Hey, I know its a bummer. Good to know that @BlackC55 isnt too far away from you though.
I call it an inspection cover but yes, I think were talking about the same part. Sits under the front of the can cover directly in front of the can gears. Its doweled so is subborn but there are a couple of areas in which you can use to pry gently to remove. I does give you a slightly better view of the chain but still a pain in the @ss. I dont have any pics of the cover I removed but I do have some of the butchered cam cover that I'm too enbarassed to share . What the removal of these stubborn injector drive you to is insane! Ive seen a few images on Google with the cover off but your right, there isnt much on the OM648.

My next move is the get a replacement endoscope, a nice cuppa tea and some patience to hopefully find the missing piece. Failing that I'm thinking remove the chain/cam and hope to get in from the top. I dont fancy dropping the subframe to drop the sump (it looks like thats the alternative anyway) Let me know how you get on.

 

[Smiley]

Sorry to hear of your woes. On the plus side you live in the right place - you are very lucky that Olly is on your doorstep - there is a good chance that other mechanics would either not have been prepared to take this sort of job on or would have made it worse trying. You will get the car back fixed; it will cost you more than you had originally thought but it is just one of those learning moments.

 

[cristispot]

Just an update, car is now back on the road thanks to Olly and PCS, which i highly recommend. They were very quick and professional and car is now purring as it should.

Don't ask me how he did it as i have no idea, and i didn't ask as i was to excited when i got the call that the car is ready

Thank you once again Olly.

 

[BlackC55]

Happy to help

 

[Smiley]

Just an update, car is now back on the road thanks to Olly and PCS, which i highly recommend. They were very quick and professional and car is now purring as it should.

Don't ask me how he did it as i have no idea, and i didn't ask as i was to excited when i got the call that the car is ready

Thank you once again Olly.

Told you

 

[McEwanClassics]

Well done Cristispot. Nice to here its back on the road. Got an update on my old girl too. So, with endoscope purchased and pushed down the side of the cam chain I found the little bleeder! Sat on top of the lower cam chain gears. There was no way that was coming out out. So managed to flick it into the sump. Replacement cam cover, new injectors fitted and oil changed she runs like a dream. Could have gone completely the other way if I hadnt have found the piece for sure.

 

[cristispot]

Glad you got yours fixed too mate. Enjoy it as much as you can because it is a really good reliable motor.

That is exactly where mine was stuck too so i have no idea how Olly got it out.