W163 Inlet Manifold Lug Damage

[ldare]

Hi
I noticed lots of wet oily **** under my EGR and on closer inspection there was quite a gap (at least 5mm) where the lower of the EGR meets the Plastic Inset Manifold.

As I started to undo the bolt I could see the metal lug through the gap turning too.

Ive now removed the EGR, cleaned, inspected and fitted again (as I need to use the car still).

Am I going to have to remove and replace the entire Inlet Manifold? I assume there's no way to fit in a new metal lug that will cut in?

Thanks
Louis

 

[ldare]

Hi I posted earlier that 1 of the 3 metal lugs holding the egr to the inlet manifold had failed. I am now assuming it can't be fixed.

I am going to have to accept I need to change the inlet manifold needs replacing.

I see two designs of gasket and I am not sure if I need one or the other or both?

Any ideas??

Ta
Louis

2003 ML 270 CDi

 

[LostKiwi]

You could try something like this:
https://rover.ebay.com/rover/0/0/0?mpre=https://www.ebay.co.uk/ulk/itm/362403949424

 

[ldare]

You could try something like this:
https://rover.ebay.com/rover/0/0/0?mpre=https://www.ebay.co.uk/ulk/itm/362403949424

I have nothing to loose, do you know the M size of these bolts?

Ta

 

[LostKiwi]

I have nothing to loose, do you know the M size of these bolts?

Ta

No idea....
I don't do diesels

 

[ldare]

M6 is my bet

 

[ldare]

You could try something like this:
https://rover.ebay.com/rover/0/0/0?mpre=https://www.ebay.co.uk/ulk/itm/362403949424

Thesr were way to narrow. Most M6 inserts are about 8mm in diameter and the mercedes ones are 12mm.

I used a 6mm drill to effectively turn the original insert into a spacer and inserted it into the hole it was from. I then drilled a 6mm hole through the plastic. I purchased a longer M6 bolt from mercedes and with a nut and washer successfully fixed the EGR to the inlet manifold at the lower of the three points of fitting where I had the issue.

Cheers
Louis