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ML write off rebuild

Discussion in 'General Mercedes-Benz Related Discussion' started by Tom-B, Feb 18, 2019.

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  1. CrustyClam

    CrustyClam Active Senior Members

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    Enjoyed catching up on your work, doing a great job.
     
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  2. Binnedit

    Binnedit Senior Member

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    Your Mercedes:
    Current: W209 CLK320 A'garde 2003, W211 E280 A'garde 2006 Past: W208 CLK 320, Yr 2000
    Always in awe of build threads.

    Great stuff Tom, keep it coming!
     
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  3. OP
    Tom-B

    Tom-B Senior Member

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    Your Mercedes:
    ML320 CDI Sport - W164 2008
    A few more parts arrived today, new grille thanks to Dronsfields and the correct PDC sensor this time... in tje right colour.
    It’s looking like the bumper is going to be a frankenstein affair for the time being, just to get the car through it’s MOT... then I can take my time and find a decent replacement.
    The inner frame is proving to be particularly difficult to source, new or used.
    62F16129-E819-460B-A733-512715D827DC.jpeg
     
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  4. Capra

    Capra Senior Member

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    Looking forward to the "reveal" post.
     
  5. daibevan

    daibevan Senior Member

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    Your Mercedes:
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    Me too.
     
  6. Andy.M

    Andy.M Senior Member

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    Your Mercedes:
    2014 GLA250 Premium Plus, Night, AMG Exclusive Leather, Driving Assistance Packs COMAND DAB HK Audio
    What ever you do, dont forget to put the thingymabob back in the watchyamacallit or you will have to strip it all down again. :)
     
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  7. OP
    Tom-B

    Tom-B Senior Member

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    Your Mercedes:
    ML320 CDI Sport - W164 2008
    So after a seemingly long time without much going on, I took a day off work last Friday and blitzed what i could.
    I must be 90% towards being ready for the MOT now.
    Just waiting on a PDC sensor bracket to go into the patched up front bumper.
    I must stress, the Frankenstein’s monster bumper is a temporary solution while I shop around for a good deal on a complete bumper assy.
    It’s looking like Poland is going to be the most likely source at the moment as there is an abundance of W164 parts for sale. I’ve always fancied a trip and have a few Polish mates who might join for a proper weekend away.

    Anyway, back to the matter in hand...
    First thing was to fix the PDC sensor plug that took a whack and stripped one of the wires:
    31BA2116-748F-4DE5-B007-9E3DDAD492E3.jpeg
    Soldered and insulated:
    A9A737DC-0BAE-4F57-BC03-42D817515CEB.jpeg

    Then got to work stripping the bumper assy apart to see what I could do with it.. cable ties at the ready!
    0C1F2D46-CC40-4FCD-8458-F1CAAB3AEBE1.jpeg
    83B6BD31-FE9B-4A1E-B6E5-7BF90B3F9A1E.jpeg
    Done:
    0E8E5EDC-8691-42BE-83E1-ADA78A8CBA4E.jpeg

    Now, I’ve missed some pics but basically I salvaged all apart from the lower valance as I picked up a replacement cheap.
    I have a lower grille too but I’m saving that as it’s brand new.

    Then got to work on the wing and bonnet... this is where Andy’s post came true. Whoops... forgot to out the plastic trim back in the door shut and didn’t notice til it was all back together!
    Fortunately the doors are really easy to remove!

    C9DB5F7A-B545-4402-9885-38FE365D7BD6.jpeg

    Had to play about with the bolts at the bottom of the wing as they were slightly bent, but a few goes and it was nicely lined up.

    FEC426A2-9690-408F-84A9-9F874716F0BA.jpeg

    The replacement bonnet came with heated washer jets which mine doesn’t have, bonus! Although I need a harness as it’s been chopped by the breaker.
    I also need to find out where they connect to, and if it’s plug and play?
    Can find very little online.
    BF5C9B40-8403-4416-A7C7-3982EB69CFAA.jpeg

    Got the bonnet on, don’t recommend this as a one man job! It’s really challenging.
    Test fitted the bodged up bumper and it seems OK.
    86C23D01-EC80-4A1D-9288-6E6E286C491C.jpeg

    The driver’s headlight needs a better fix on the top bracket as it broke off again but I think I’ve sorted it.
    A new horn arrived today, grille is here, so just waiting on that PDC bracket coming from Latvia and she’ll be ready for MOT time.

    Once the MOT is done, the finessing begins.
    - Noticed there’s a small amount of smoking from behind the offside airfilter housing so I suspect some kind of oil seal resides there.
    - Turbo/Intake big red oil seal needs replacement and I have one already. Just need some instant gasket.
    - While above is off I’ll do the fuel filter and swirl flap resistor. Have the resistor, ordered some fancy 3pin plugs to do a proper job of it.
    - Engine Oil change, trans oil change, air filters
    - A damn good clean inside and out
    - A nearside rear tyre soon to match the new offside one!

    And no doubt, a few more things i’ll pick up along the way.
     
  8. Wighty

    Wighty Senior Member

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    Fantastic work buddy , really coming together .
    What was the 3 pin plug you ordered for the "resistor fix"? , I'm interested as mine is just taped with electrical tape at the moment .
     
  9. OP
    Tom-B

    Tom-B Senior Member

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    Your Mercedes:
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    Cheers, I ordered these:
    7AE1C9A5-90C3-4AB5-AA94-AF6319394C44.jpeg 1F150F1A-6AC9-44CF-BA7A-D90F75A40D8E.jpeg

    They come in 10s, I struggled to find singles... if you cover me for costs I’ll send you one of mine if you like?

    I was planning on “potting” the resistor to make it look nice and neat, but you can just push them in I believe.
     
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  10. OP
    Tom-B

    Tom-B Senior Member

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    Your Mercedes:
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    Forgot to mention, white van in the pics was Mark from M-Fix paying a visit again to leak test and regas the A/C system.
    15 mins on test and no leaks, measures 5 degrees at the vent which I’m more than happy with.
    So now I have Bahamas heat for winter and Arctic ice for summer.
    Mark also fixed a very old electrical gremlin on the S13 too, only one high beam was working which was traced back to carbon build up on the stalk switch contacts.. so overall, happy!

    Am very keen on a heated steering wheel retrofit at some point though!
     
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  11. Andy.M

    Andy.M Senior Member

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    2014 GLA250 Premium Plus, Night, AMG Exclusive Leather, Driving Assistance Packs COMAND DAB HK Audio
    Don't say I didn't warn you about the thingymabob!! :p

    Loving this build. It's a million miles out of my league :)
     
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  12. Wighty

    Wighty Senior Member

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    That's a kind offer buddy , I'll search the garage in the next few days , if I don't find anything suitable to "cap off "the resistor I'll get back to you .
     
  13. OP
    Tom-B

    Tom-B Senior Member

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    Your Mercedes:
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    So unfortunately a slight balls up with the order meant I only received x1 set of the plugs not the x10 that I ordered.. never mind, the remaining 9 are on their way and I can still get to work sorting my car out in the mean time.
    D7D27B7E-1C57-4747-87B5-183EE417A846.jpeg

    Service kit on it way, going to do the fuel filter while the top is off and the big red seal.
    Have a bit of gasket sealant too to enduse no oil is getting past it.
    Oil (10 litres to support the 8.5l capacity!) and filter. And even managed to get a replacement PDC holder from Euro car parts that comes with an adhesive pad.
    Have ordered a set of Ken and Norman air filters but some recent reading says they aren’t worth the money... so I’ll probably exchange them for some OE parts and invest the difference elsewhere.
     

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  14. OP
    Tom-B

    Tom-B Senior Member

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    Your Mercedes:
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    Feels like it’s been a long time since I last provided an update, I’ve been away a lot so have had to do bits and pieces as and when possible.
    I’ve been able to get the patched up bumper fitted along with the new grille and get her into a state of being able to drive.
    2064D5CC-45E4-4A22-BC41-79EFBD0AB76F.jpeg

    Some futher testing on private roads has revealed a few unforseen issues.
    How I didn’t notice how low the OSF is sitting is beyond me! Some further investigation led to a shock discovery. (Like that one?)...
    FCB1CEF3-5BF3-4931-9944-5BE812007EDB.jpeg
    The pig tail on the bottom of the spring has broken off, leaving the car riding on the bump stop.
    F3C871FD-C581-4F35-8E07-D34148D36CC3.jpeg
    Old one vs a part from a low mileage breaker...
    Noticed that the brake flexi hoses had seen better days so fitted some new ones while I was down there.
    2CDB6FDF-CEE5-4B7E-BB16-28FBC0C67EED.jpeg
    Now with correct ride height!
    5DBFBEE3-8DAB-4DD1-877D-10AAF3067BF5.jpeg

    A scout at the back also revealed a broken rear spring too.. so a pair of new sachs OE spec replacements will be going on later.
    Hard to see as it’s covered by the rubber.
    EDB9A95D-FDE5-4BBF-8578-C33745D62AC4.jpeg

    I’ve found the culprit for the oily smoke near the exhaust, the PCV valve is leaking and is actually classed as a service item, so i’ll be fitting the newer version when it arrives from sunny Poland!
     
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  15. V6Matty

    V6Matty Senior Member

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    You’ll get to know that Mercedes springs are made of cheese and tend to break without warning.
     
  16. Blobcat

    Blobcat Moderator

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    Not just Mercedes, they're all like it now. Take a walk up most roads and you'll find bits of springs lying at the side of the road. Even more prevalent if there's a bend or few bumps around as the broken bit gets bounced out onto the road.
     
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  17. OP
    Tom-B

    Tom-B Senior Member

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    Yeah I can’t help thinking that the problem is exacerbated by the abundance of cheap aftermarket springs on the market now.
    The Sachs ones are made in the Netherlands which gives me some reassurance.
    Time will tell!
     
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  18. daibevan

    daibevan Senior Member

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    Your Mercedes:
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    They only last if the roads are flat.
     
  19. BillyBoy

    BillyBoy Senior Member

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    If only it had AirMatic - no chance of any suspension problems if you had that...
     
  20. V6Matty

    V6Matty Senior Member

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    :eek::eek::eek::eek::eek::eek::confused::confused::confused::confused::p:p:p
     

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