Inlet port shut off motor delete (CDI2)

[Alex Crow]

Hi Guys,

Does anyone know where to get the below Torx screw from, dealers do not sell them independently it comes with the manifold, but all i have done is lost the screw. attached on inlet port shut off motor - it goes into the metal clip onto the manifold.

I have attached the picture as to which metal part i am talking about..??
Pleae help otherwise i will need to buy the whole manifold for £1500 rather than a simple screw. please

It will be a standard size, probably M4, so should be available from various places, although you may have to buy 100!

 

[Alex Crow]

Hi! I have a 2000my W638 V220cdi.

I just switched to a used ECU in the car and then came up error code p1189 and the car goes in limp mode.
I suspect it may have been a inlet port valves on the engine the ECU is coming from. it's not inlet port valves on my car. Is there an opportunity to solder a resistor in to my ecu? And does anyone know which pins on the ECU I must solder to?

Difficult, not knowing which ECU you now have, but...

Try pins 22 and 33 in plug 4.

 

[Wellseyoffroad]

Swirl flaps

Hi I just removed flaps today tapped holes 16 mm bolts cut to length and lock tight in, it cost 30 quid for a 14mm drill a number 2 tap lock tight and bolts, oh and a coat hanger. To wire the bolts, I drilled the bolt heads, after power washing the thing first I filled it with de greaser and used a flexi handled tooth brush I found in the bathroom there is six in our house no one is shouting yet, if it's the wife's it's her car any way, I am going to put the motor on top of the manifold as it still working, watch this space, also fitting dealer gasgets, thanks for all the help on this site.

 

[Wellseyoffroad]

Swirl flap mod

Done swirl flap mod, still got power loss because we ran it with the problem when we'd lifted the actuator arm with an elastic the car went well. Until one broke off. I assumed once the mod was done we'd be off, but no improvement. I removed the air filter so I could see the variable vain opperater sucked the air pipe and it works, air pipes are sucking swapped those 2 electric valve things over, no change. Problem sounds very similar to air mass ???? The posts suggest tempory removal doesn't have any effect till a new one is fitted is this correct,

 

[KimHaugli]

E270

Hi. I have the problem that the Inlet Port Motor makes some strange noises and jerks a littlebit, before shutting down. Noises are there constant. Limp mode, not possible to delete the error codes.

Error code P2526 - Vacuum Reservoir Pressure Sensor Circuit Range/Performance
P0243 - Turbo/Super Charger Wastegate Solenoid "A"

I have therefore thought of doing the resistor mod, but u guys do talk about using resistors at the motor, fuse box and the ECU. Is it enough for me to just use a resistor on the two wires at the motor, or is it simpler to do it at the ECU? Pretty thight in the engine bay..
If easier to do at the ECU, do anyone have some pictures?

-Kim.

 

[Mr Hatt]

motor delete

Hi Alex
So I bought an E280 that Merc quoted £5k to fix due to "Turbo and actuator damage" because I could see no turbo issue just a limp home mode issue that needed more investigation, on stripping the top end I found that turbo is perfect, actuator movement is perfect and EGR is clean so moved deeper to find flap linkage so worn that only two flaps opened on full motor/ linkage movement leaving four semi-closed, best option within budget is the delete you carried out and your post is invaluable thank you but I need to know a bit more about the motor part, is there a way I can test the motor on the bench ? it seems smooth if moved manually and, not having a wiring diagram, which wires in the plug need the resistor placing across them ?
thank you for a great post by the way Steve

 

[Alex Crow]

Bench testing can only be done if you have a PWM power supply, so not practical.
The resistor goes between the live and signal wires - approx grey and red, ignore the brown earth.
The flaps can be jammed in the open position if you have the manifolds off btw.

 

[star]

I'd do the oil cooler seals while you have the manifolds off.

 

[Alex Crow]

I'd do the oil cooler seals while you have the manifolds off.

Another nice little earner, thanks Mercedes for the OM642, from all the specialists!

 

[dmitry_sorokin]

B96 sensors

Hi All,

I've done the resistor trick, disconnected the motor and fixated the link bars in flap-open position. That worked great, thanks to Alex's suggestion. However I've got bot B96/1 and B96/2 sensor errors reported and check engine light on because of these. I guess the sensors are OK, it's just the computer thinks that the sensors do not register different positions (flap-closed positions I think in particular) in case the signal from the computer goes to the motor to change the position and sensors do not register that although computer thinks motor did that (of course there's a resistor that tricks the computer).

Any way to trick the computer to think that sensors work as well or maybe disconnect these altogether?

Thanks a lot!

 

[Alex Crow]

Hi All,

I've done the resistor trick, disconnected the motor and fixated the link bars in flap-open position. That worked great, thanks to Alex's suggestion. However I've got bot B96/1 and B96/2 sensor errors reported and check engine light on because of these. I guess the sensors are OK, it's just the computer thinks that the sensors do not register different positions (flap-closed positions I think in particular) in case the signal from the computer goes to the motor to change the position and sensors do not register that although computer thinks motor did that (of course there's a resistor that tricks the computer).

Any way to trick the computer to think that sensors work as well or maybe disconnect these altogether?

Thanks a lot!

Am struggling with this one - UK spec cars have no B96 sensors, ie no flap position sensors.
Presumably this is part of the wonderful US emissions requirements?

 

[gothic_merc]

I am currently about halfway through removing my flaps. Its been a long job so far. Have 5 of the 6 flaps out but one was in a bad way as it had started to fail and the heads of the torx screws are quite worn and very stiff. The other came out without any hassle. The whole manifold is bad. I am using a spark plug brush to clean as far down as I can. A foam degreaser too which I can aim down the pipes and seems to be clearing it slowly.
Roll on getting it all back together, with the motor removed and the egr disabled

Jon

 

[dmitry_sorokin]

Am struggling with this one - UK spec cars have no B96 sensors, ie no flap position sensors.
Presumably this is part of the wonderful US emissions requirements?

Thanks for reply Alex.
Not sure if this has to do with any US/Canadian emission requirement, but all cars with OM642 engines (I've got ML320 and R320) have these sensors.

Had to order right intake manifold with the motor from eBay...

 

[Marxs1]

Hi Guys,
Have looked everywhere however can't find the step by step instructions to taking off the inlet manifold, could someone post them including torque specs please.
2002 W203 220cdi.
Cheers
Mark

 

[Genesis87]

Hi guys. Nice tutorial here. My car had an air leak from inlet manifold. So i decided to take it out. When i did i only found 3 flaps? 2 were missing. I checked the holes and they seem to be fine. The car was running fine other than the air leak obviously it was from flap holder holes. Any ideas what i should do ? Im worried the 2 went down thru holes when i took it off.

 

[3LV6]

This is my first post so many thanks to Alex and everyone else for sharing all their very useful information in this thread.

I have a 2006 CLS 320 CDI 122K miles which seems to have the same problems that others have described as being fixed by the swirl flap delete/resistor mod. I got the CLS about 3 years ago with about 95K miles on it and I suspect it has always had this problem.

When I first got the car it probably only went into limp mode once in the first 6 months and didn't show any engine management light warning. For the first 2 ½ years the limp mode problem usually happened under strong acceleration and went into limp mode with a judder, it almost always went away just by restarting the engine. More recently the issue has happened more often, it doesn’t always resolve itself by restarting the engine and sometimes the engine management light comes on. It now also seems to get the problem from starting off and there is no judder. When it doesn’t have this particular problem the car drives fantastic, lots of power and smooth acceleration.

I’ve had 3 services done at independent Merc garages since I’ve had the car and always had any recommended jobs done but they have never mentioned a fault like the above so recently I got myself a cheap OBDII device and DashCMD on my smartphone. The error that shows up is

“p2015 intake manifold runner position sensor/switch circuit range/performance bank 1”

So I’ve come to the conclusion that the swirl flap delete/resistor mod will improve and hopefully solve my issue.

I’m not very mechanical so I’m not sure I’d trust myself to do the job correctly so I called a local independent merc garage to ask if they would do the job for me. They said they wouldn’t and they don’t recommend doing the job because they can’t guarantee that it won’t cause any issues. They also quoted £450 for replacing the motor and they suggested I go in to get the fault codes read by them.

So my question to anyone who can help is, can they recommend any garage that would do swirl flap delete work/resistor mod in the Northwest near Warrington (where I live) or near Nottingham (where I’ll be working for the next few weeks). Thanks in advance to anyone who can point me the right direction.

 

[spcamno]

Thanks for reply Alex.
Not sure if this has to do with any US/Canadian emission requirement, but all cars with OM642 engines (I've got ML320 and R320) have these sensors.

Had to order right intake manifold with the motor from eBay...

Hi dmitry_sorokin,

Were you able to fix yours without replacing the manifold?

Brother-inlaw has a 09 ML320 Bluetec throw P2004 and P2005 (intake manifold runner stuck open bank 1 and bank 2) and thinking most likely its the same issue everybody have.

Would like to know if its possible to get it fix without replacing both manifold.

Thanks

 

[turbopete]

i cant comment about the manifolds, but a 2009 vehicle is totally different to the vehicles to which this mod refers to, and this mod will NOT work on a 2009 vehicle im afraid

 

[spcamno]

I just wanted to verify that with the 08 ML320CDI W164 I can make this modification. The car has the dreaded Oil cooler leak and will be going in to get the seals replaced. At the same time I would like to remove the flaps and the bypass the shutoff motor due to the reported issues surrounding it. Unfortunately there is no warranty on the car anymore. I've been suspecting that something has been wrong for while, since I always have to top up 1-2 liters of oil between changes. But every time it has gone into the dealer they insisted that there were no issues and this was normal. Now of course that the car is out of warranty there is an issue.
Anyway, I just wanted to make sure that I can make this change as my mechanic said there might be an additional sensor on my model and that this cannot be bypassed, but he won't know until he tears it down.

Hi dieselsyndrome,

Any update on your repair?

Were you able to use this mod to fix the issue?

My brother in-law has a 09 w164 ML320 Blutetec (same engine as your OM642 except with the use of adblue) and has the same problem you have and looking for solutions.

Thanks for your help.

 

[Alex Crow]

Hi one and all.

We have fitted many 4.7kohm resistors to OM642 engines, as opposed to replacing the M55 motor and yes, sometimes manifolds as well.
It seems to work just fine on all the UK spec 642 engines we have fitted it to so far, and we would expect it to work OK on even a 2009 vehicle (as mentioned above). We have received no reports of detrimental effects to fuel consumption or drive-ability.
I note that this mod is very popular with the Chrysler and I think also Jeep communities where Mercedes OM642 engines are installed.

Some of our customers run older cars on tight budgets, and with this mod we have been able to offer an effective low cost solution to an otherwise expensive repair.