C220 CDI cuts out under acceleration

[mbyrnes]

Hi,

I have a C220 CDi 2003 that cuts out if you accelerate a little more than normal. It dies completely and EPC error comes up on the dash. Car will start straight away and will drive fine normally. Even using the cruise control stalk to accelerate will sometimes cause it to happen. If car is driven with a light foot it go on and will speed up excess of 100 mph. There is a puff of black smoke when it happens. This fault was worse at it would happen exactly at 40mph. Had the injectors out and checked with good pattern on all. They were put back in with new seals. Pump in tank taken out and cleaned. Car got a good service and this brought us to this point. I have had the high pressure pump off and swapped with a pump from from a manual C220. Car drove great for a while and same happened - died under pressure, I think because engine was cold. Gets worse as the engine gets warmer. I think myself air is getting somewhere. Any ideas, help or suggestions would be great. Car is in Ireland. Thanks, Michael.

 

[Steve@Avantgarde]

I have had this issue before and it turned out to be the throttle pedal. You possibly may have the same issue. Have you had the car put on a Star Machine?

I dont think it is a fuel related fault as I dont think you would see an EPC error on the dash when the fault occoured, if anything the engine management light would show.

 

[Alex Crow]

hi michael, have you any record of the fault codes? how were the injectors checked (ie was the leakoff under high pressure measured)? the fault codes really are the place to start.

have a read here for my first guess though....http://forums.mercedesclub.org.uk/showthread.php?t=64986

 

[mbyrnes]

Hi Guys,

Thanks for the replies. Alex I am waiting for the mechanic to get back to me with fault codes, will post as soon as I have them. Just to add to the help with diagnosis it seems more likely to happen if the car is warmer. Also the car drives better and is more able to take acceleration when driven in tiptronic (or Seq) but will still cut out if pushed hard enough. Its like if it is trying to do a double knockdown it will cut out.
Again, thanks for the replies.

Michael.

 

[dieselman]

Check the pipes from the fuel filter for air leaks and that the filter isn't blocked.

 

[mbyrnes]

Hi all,

Drove car this morning and first chance I got to give it lots of acceleration, I did and the car drove great, loads of power and no cut out. Drove on as normal for 15 mins and tried to accelerate with a little aggression and engine died with EPC error. Does anyone have any ideas as to why the car would drive fine cold and cut out when hot? Still waiting for mechanic to get back to get fault codes. Hoping to do a high pressure leak off test this week to see if an injector shows up as faulty.

Thanks,

Michael.

 

[Alex Crow]

...... Does anyone have any ideas as to why the car would drive fine cold and cut out when hot? ....

i understand what you are asking - has anyone had exactly this before. typically on this forum, if you have a well known or common problem you will get a zillion identical replies, which is very helpful. i think however in this case you will have to wait untill the codes are read.

and as for the leak off test - make sure it is done whilst constantly revving the engine up to max rpm and back with full throttle, just doing the test at idle will not pick up this fault.

 

[dieselman]

Have you changed the fuel filter yet. I've known nearly exactly this situation on a 320 CDi due to blocked filter.

 

[mbyrnes]

Hi,

Got the car on a star machine today and these are the CDI-2 results....

P1187-032 Rail pressure monitoring Control variation
P1664-002 Electric heater booster Equipment fault
P0100-001 B2/5 (Hot film mass air flow sensor) The signal voltage is too low
P1190-008 Y74(pressure control valve) Open circuit in wiring Signal wire
P0190-002 B4/6 (Rail pressure sensor) The signal voltage is too high.
P1470-016 Charge pressure control Positive control variation [ Charge pressure is too low. ]

There are loads of other faults stored like under ETC...

P2001 Component N15/3 (ETC [EGS] control unit) is defective..

Anyway the common rail diesel injection ones are the most important I presume...
I really really hope these faults will help someone pin point the fault or at least.
The garage today highly recommended changing the airflow meter at £110+VAT. That is getting done tomorrow.

Thanks again for your help so far, really appreciate it...

Michael.

 

[mbyrnes]

Oh and I've been told the car got a full service including fuel filter.

Michael.

 

[Steve@Avantgarde]

Were the actual values checked of the MAF to see whether the readings to the Engine ECU are in spec?

I would advise also carrying out a smooth running test on the star to check the injector hub value. I dont think this is a MAF issue.

 

[Alex Crow]

as above, it is great we now have the fault codes, but they all need following up with live data and guided tests! i suspect some of these codes have been inadvertently logged by unplugging stuff, and please note.......the maf sensor will NOT cause the engine to cut out.

 

[mbyrnes]

Hi all,

Had all the faults cleared yesterday. Car cut out three times on way home yesterday. Going to try and get the faults read again today and see what is current. Will also pass on your recommendations about doing a smooth running test and also check values going to ECU from MAF.

Thanks,

Michael.

 

[Alex Crow]

that is a good way to go, will have another think when you post the new codes - my guess is that p1187-032 will be logged.

 

[frizby66]

Had exactly the same fault on my ML270 a few months back. Was faulty injector which was dropping the pressure on the common rail and making the EPC light come on and then cruise to a halt. Siwtch off and then start again and off it would go until you accelarated a bit harder and the same again. Changed injector and has never done it since!

 

[mbyrnes]

Thanks frizby66 and Alex.. I feel this is going somewhere now and hoping the end is nigh.. looking forward to driving this car and enjoying it... How much are injectors and do they need coding or can they be popped in? Michael.

 

[mbyrnes]

Hi all,

Diagnostics were ran again today and as stated by Alex the following occured...

P1187-032 Rail pressure monitoring Control variation.

They fitted MAF they ordered today anyway and I drove car away. Went down the road a little and fault re appeared. Need a new injector I think. Car booked in for leakoff test on fri...

Michael.

 

[mbyrnes]

Hi all,

What type of injector do I need for my car? I think the engine type is OM611.962. It is a 2003 C220 CDi saloon elegance auto. Again thanks for all your help.

Michael.

 

[mbyrnes]

Hi again,

Really really disappointed now.. rather than trying to figure out what injector I needed and relying on the garage to tell me what injector was failing, I cancelled the leak off test with garage and booked car in with a diesel injection specialist, just made more sense. Told them all I knew up to date and offered the advise I received on this site. They agreed with you and went straight for injectors. Now these people are highly respected in my area as being the best in the business. They took all the injectors out and bench tested them. Two failed at high pressure leak off and were reconditioned and then passed. Put these back in and car was warmed up. Same poxy fault came back. Car cut out with EPC error when hot. They changed the sensor and still the same. When I got off the phone they were in the process of removing the high pressure pump for testing. Now they have all the latest equipment from Bosch and Seimens. They do know what they are at. But now even they are starting to scratch thir heads... Any more advice??? At wits end now...

Thanks,

Michael.

 

[Steve Taxi]

Had a similar problem with the same car as yours it was the fuel pressure valve at the back of the fuel rail, remove it and there is a tiny o ring that splits.