Ml270 , 2003 , project

[vincentfishing]

BOUGHT 2003 ML 270, PROJECT FOR BACK GARDEN.VERY LITTLE RUST NO DENTS, JUST SCRATCHES/WEAR AND TEAR, MOT TILL 5/2020. £680.
KNOWN FAULTS. BROKEN FRONT BUMPER AND BLACK SMOKE ON HARD ACCELERATION. JUST TOOK OFF ENGINE COVER AND DISCOVERED THE ' BLACK DEATH ' IVE HEARD ABOUT. NOT TOO BOTHERED, WILL CLEAN SOON AND REPLACE/ RESEAT INJECTOR AND DO A LEAK BACK TEST. IN THE MEANTIME WILL BE LOOKING FOR A FRONT BUMPER PAINTCODE 359.

 

[Wighty]

View attachment 53647 View attachment 53648 View attachment 53649 View attachment 53650 View attachment 53651 View attachment 53652 BOUGHT 2003 ML 270, PROJECT FOR BACK GARDEN.VERY LITTLE RUST NO DENTS, JUST SCRATCHES/WEAR AND TEAR, MOT TILL 5/2020. £680.
KNOWN FAULTS. BROKEN FRONT BUMPER AND BLACK SMOKE ON HARD ACCELERATION. JUST TOOK OFF ENGINE COVER AND DISCOVERED THE ' BLACK DEATH ' IVE HEARD ABOUT. NOT TOO BOTHERED, WILL CLEAN SOON AND REPLACE/ RESEAT INJECTOR AND DO A LEAK BACK TEST. IN THE MEANTIME WILL BE LOOKING FOR A FRONT BUMPER PAINTCODE 359.

I've stuck the kettle on buddy , awaiting the next stage

 

[Taffy7hfa]

Nice ! Bumper looks quite repairable as well.

 

[joderest]

looking at pictures the engine cover has not been off for a while, wonder how they changed oil filter at service !!!!
With a bit of work the front bumper could be repaired and painted, they seem to fetch a lot of money still on fleabay.
looks a good project at that price.
same year as mine, thought it may be worth a little more than that. ( it has no sign of leaking injectors) dam, should not have said that, it will now !!!!

 

[vincentfishing]

Heated engine and cleaned off tar as best as could till next time, injector holding down bolt is allen key head so may be a botch , hope thread is ok for normal stretch bolt, probably going to have another go at freeing injector tomorrow, did quick 1 min leak off before disconnecting injector , all around the 10ml
mark , which i think suggests all ok and probably black smoke is another problem to move onto after fixing injector seating.

 

[vincentfishing]

Heated engine and cleaned off tar as best as could till next time, injector holding down bolt is allen key head so may be a botch , hope thread is ok for normal stretch bolt, probably going to have another go at freeing injector tomorrow, did quick 1 min leak off before disconnecting injector , all around the 10ml
mark , which i think suggests all ok and probably black smoke is another problem to move onto after View attachment 53774 View attachment 53775 View attachment 53776 fixing injector seating.

Have just been out and cleaned a bit more and got the injector bolt and clamp out. When looking down bolt hold it appears that a section of snapped bolt is about 30mm down hole , the bolt i got of fleabay is about 85mm ish , so about 40mm of broken bolt stuck in(15mm for clamp 30 mm down hole) ?? Can anyone confirm new bolt is correct length.

 

[vincentfishing]

Couple of better pics , seem to be the thread stops and a hollow bit around it at 30mm deep ?

 

[vincentfishing]

Couple of better pics , seem to be the thread stops and a hollow bit around it at 30mm deep ? View attachment 53780

Have now removed injector by firstly levering fuel inlet housing mm by mm back and forth till it gradually loosened (with some brake cleaner soaking around inj for a couple of hrs)then used big injector removal socket to continue twistiind whilst levering with screwdriver, didnt take too long thankfully.
You can now see broken bolt a bit better

 

[Taffy7hfa]

Thats a shame, yet another botched injector repair, needs drilling out and a Time-cert. not something I would attempt, plenty of specialists out there that do that sort of stuff all the time though. Good luck.

 

[vincentfishing]

Thats a shame, yet another botched injector repair, needs drilling out and a Time-cert. not something I would attempt, plenty of specialists out there that do that sort of stuff all the time though. Good luck.

Having read your reply and looked back at picture,, is that an insert that is already in and the reason a short bolt was what I took out ,because the insert only requires a short bolt ??

 

[vincentfishing]

if it is a timesert type insert, what torque would be required to tighten a short bolt that wouldnt have the stretch of a long bolt???
going to attempt to get broken bolt out in the hope I can use standard length stretch bolt and torque accordingly

 

[Taffy7hfa]

Best information I can give is that unless you use a genuine mercedes stretch bolt correctly fitted the injector seal will always fail, others have tried using larger diameter bolts, it just won't work at least not long term. you will need to use extreme care removing the remains of the old bolt, I don't think there's too much metal between the bottom of the bolt hole and the water jacket.

 

[vincentfishing]

Best information I can give is that unless you use a genuine mercedes stretch bolt correctly fitted the injector seal will always fail, others have tried using larger diameter bolts, it just won't work at least not long term. you will need to use extreme care removing the remains of the old bolt, I don't think there's too much metal between the bottom of the bolt hole and the water jacket.

ITS DEFINITELY AN INSERT AND LARGER DIAMETER, and insert not very deep because of stuck /broken bolt so i dont think i have much choice , other than if i can get broken bit out removing insert somehow and putting correct diameter insert thats longer, think i might have to live with current insert torqued to about 18nm according to internet and hopeit holds.
In the meantime have removed airfilter looks pretty old to me and removed pipe to egr both are pretty filthy.
Can i remove EGR without removing the steel box that runs of it or does the whole lot need to come out?

 

[Taffy7hfa]

Hi Vincentfishing, once you remove the 3 torx bolts that connect the EGR to the inlet manifold it just pulls off the heat exchanger its a push fit there are no fastenings.... Re- the snapped stretch bolt , I think if it were mine I would be trying to remove the remains of the original bolt and fit a Time-cert so the correct stretch bolt can be fitted, even with less available threads a Time-cert repair is going to be much stronger than any thread cut in the ally head.

 

[vincentfishing]

Hi Vincentfishing, once you remove the 3 torx bolts that connect the EGR to the inlet manifold it just pulls off the heat exchanger its a push fit there are no fastenings.... Re- the snapped stretch bolt , I think if it were mine I would be trying to remove the remains of the original bolt and fit a Time-cert so the correct stretch bolt can be fitted, even with less available threads a Time-cert repair is going to be much stronger than any thread cut in the ally head.

Hi.yep might still try and get broken bolt out, if i manage to how do i get existing insert out drill it out or wind it out somehow, all new to me ,one of the few things i havnt done on a car.
In the meantime i connected up the injector that was blowing past the seal on the outside of engine to test it and it appears fine still chucking out black smoke running on 4 cylinders when reving so not an injector problem ,so on with sorting out cleaning up seating for putting enjector back

 

[AnthonyUK]

There is an interesting video set on YouTube from Mercedes source about saving an old diesel called Digby.
I found out a lot about that type of Diesel engine from them.

 

[Taffy7hfa]

It looks like the thread insert has been fitted into the rocker cover as well as the head,which is not ideal . i'm pretty sure that a competent engineer/diesel specialist could wind out the remains of the bolt and the Helicoil/Time-cert that has been fitted at the top of the hole.
https://www.injector-removal-service.co.uk/

 

[vincentfishing]

Hi, Don't like to pay to have it done when I should be able to do it myself, so will do a bit of research on the web, but guessing a stud extractor will wind it out, the question is will a longer insert use the same thread before self cutting below it ? First thing is to get broken bolt out.

 

[Taffy7hfa]

Fair enough, it's not rocket science after all .although I wouldn't want to have to replace the head on one..

 

[vincentfishing]

cleaned all the yuk out of the EGR today, tested it with my vacuum pump and it opens but slowly closes as the vacuum pressure drops,, don't know if its designed to do that or it has a slight leak, if its a leak don't know weather it will affect the operation or is the vacuum supplied continuously to it which may hold it open or is the vacuum switched 'on' to open it then stopped expecting it to stay open until the call to 'off' the pressure and release valve ??
don't know if that made sense?