1. This site uses cookies. By continuing to use this site, you are agreeing to our use of cookies. Learn More.

ML270 swirl flap question

Discussion in 'Engine, Drivetrain, Fuel and Exhaust' started by tttonyyy, Apr 8, 2019.

  1. tttonyyy

    tttonyyy Active Member

    Messages:
    32
    Likes Received:
    38
    Joined:
    Mar 31, 2019
    Location:
    Southampton
    Your Mercedes:
    '03 ML270 (60k miles!)
    Hiya, I've picked up a ML270 of 2003 vintage with 60k on the clock, but it needs some attention before I can use it as a family runaround. Swirl flaps and black death onset primarily.

    The threads here on removing the swirl flaps are very useful so thank you all for those.

    I've got the inlet manifold off (not without some swearing) and removed the swirl flaps. They were very brittle and everything was crumbling away, unfortunately including the surrounds that insert in the manifold ports around the flaps. I can see how normally they would hold the rubber seal to prevent it deforming when clamped up against the inlet. How important is that, as I will need to make up some sort of replacement? Or can I get away without them?
     
    th3h1ghlander likes this.
  2. bembo449

    bembo449 Senior Member

    Messages:
    2,886
    Likes Received:
    579
    Joined:
    Jan 2, 2012
    Location:
    lincolnshire
    Your Mercedes:
    w221 320cdi , r170 23k , range rover vogue , insignia vxr , shitron dispatch
    I know when I did the flaps on my old ML , I just used large bolts with a runner grommet on each as a seal , could you add pictures so we can see exactly what you are talking about pal
     
    th3h1ghlander likes this.
  3. OP
    tttonyyy

    tttonyyy Active Member

    Messages:
    32
    Likes Received:
    38
    Joined:
    Mar 31, 2019
    Location:
    Southampton
    Your Mercedes:
    '03 ML270 (60k miles!)
    Good plan - it slots into the bits marked in red and faces against the metal around the engine ports.

    [​IMG]
     
    th3h1ghlander likes this.
  4. OP
    tttonyyy

    tttonyyy Active Member

    Messages:
    32
    Likes Received:
    38
    Joined:
    Mar 31, 2019
    Location:
    Southampton
    Your Mercedes:
    '03 ML270 (60k miles!)
    I could 3D print some replacements in ABS. With the holes that spindle would normally go down blanked. Only trouble is that ABS melts at 105C, how hot does the head get?
     
    Last edited: Apr 8, 2019
  5. OP
    tttonyyy

    tttonyyy Active Member

    Messages:
    32
    Likes Received:
    38
    Joined:
    Mar 31, 2019
    Location:
    Southampton
    Your Mercedes:
    '03 ML270 (60k miles!)
    Laying awake thinking about it - I've got a cunning plan! Will post pictures if it works.
     
    om613, Wighty and Blobcat like this.
  6. Wighty

    Wighty Senior Member

    Messages:
    5,710
    Likes Received:
    2,923
    Joined:
    Aug 4, 2016
    Location:
    Sunny Essex
    Your Mercedes:
    W211/E320cdi/2009 and CLK200k 2009
    Ive done the laying awake thinking , not always got a cunning plan at the end of it though :D
     
    tttonyyy likes this.
  7. OP
    tttonyyy

    tttonyyy Active Member

    Messages:
    32
    Likes Received:
    38
    Joined:
    Mar 31, 2019
    Location:
    Southampton
    Your Mercedes:
    '03 ML270 (60k miles!)
    Fingers crossed. Interesting to note though that the photo shows the intake material is PA6-GF35 which is a polyamide (the PA bit - aka "Nylon 6") and is 35% Glass Fibre reinforced.

    JB Weld also happens to be based on a Polyamide hardener with silicate fillers and a similar thermal profile - seems like a reasonable material match.
     
    th3h1ghlander likes this.
  8. iljalways

    iljalways New Member

    Messages:
    5
    Likes Received:
    3
    Joined:
    Mar 14, 2019
    Your Mercedes:
    R320 CDI 2007 OM642
    I did my flap delete on my om642, I love it,
    I just took my Tig and welded the holes shut.

    Put a 4.7k resistor in place, no problems anymore

    Sent from my SM-G965U using Tapatalk
    [​IMG]
     
    ajlsl600 and Wighty like this.
  9. OP
    tttonyyy

    tttonyyy Active Member

    Messages:
    32
    Likes Received:
    38
    Joined:
    Mar 31, 2019
    Location:
    Southampton
    Your Mercedes:
    '03 ML270 (60k miles!)
    I was very tempted to get a Merc with the OM642 but I've got a friend with one that has an oil leak from the oil cooler and it looks like a deep delve into the V to get to it to change the seals. Nice sounding engine though and some pull!

    I've been pondering the inlet manifold issue and thinking about casting the missing fittings in place with JB Weld, which is wonderful stuff (good over 200C!) - but I'd have to dilute it with acetone to get it to run into place, which can lead to shrinkage and reduce the strength. Anything that could potentially come apart with aging makes me nervous.

    In the end I've opted for this - stainless steel strips carefully formed to follow the port profiles and support the seals.

    [​IMG]

    To be honest the seals are pretty solid anyway so it's probably unnecessary, but I'll feel better knowing they're there.
     
    Last edited: Apr 12, 2019
  10. OP
    tttonyyy

    tttonyyy Active Member

    Messages:
    32
    Likes Received:
    38
    Joined:
    Mar 31, 2019
    Location:
    Southampton
    Your Mercedes:
    '03 ML270 (60k miles!)
    Anyone know the torque setting for the OM612 inlet manifold bolts?

    (Or better still, where I could find an engine manual!)

    Thanks :)
     
  11. W245207

    W245207 New Member

    Messages:
    4
    Likes Received:
    3
    Joined:
    Mar 28, 2019
    Location:
    UK
    Your Mercedes:
    W245 B180 CDi 2005
    tttonyyy and Wighty like this.
  12. OP
    tttonyyy

    tttonyyy Active Member

    Messages:
    32
    Likes Received:
    38
    Joined:
    Mar 31, 2019
    Location:
    Southampton
    Your Mercedes:
    '03 ML270 (60k miles!)
    That is brilliant, thank you very much. That diagram and link also gives me a fighting chance of getting the right length bolts back into the right holes too!
     
  13. th3h1ghlander

    th3h1ghlander Senior Member

    Messages:
    360
    Likes Received:
    92
    Joined:
    Mar 23, 2016
    Location:
    Chesham
    Your Mercedes:
    C-Class C270 CDI (W203)
  14. OP
    tttonyyy

    tttonyyy Active Member

    Messages:
    32
    Likes Received:
    38
    Joined:
    Mar 31, 2019
    Location:
    Southampton
    Your Mercedes:
    '03 ML270 (60k miles!)
    I've got a hold of the WIS VM which looks pretty useful.

    Been making some progress and I love posting photos of car work up because you never know who might find it useful in the future so here goes.

    Stainless blanking bolts M16x20mm drilled both sides to key into the JB weld to stop them working loose:

    [​IMG]

    JB Welded into place

    [​IMG]

    With inlet gasket rubbers and hand-crafted stainless rubber supports:

    [​IMG]

    Socket chopped off swirl flap motor:

    [​IMG]

    "Why yes Mr ECU I'm definitely a working swirl flap motor" resistor, 4k75:

    [​IMG]

    I split and re-wrapped that bit of loom so the resistor can be placed somewhere accessible in case I got the wrong terminals.
     
  15. OP
    tttonyyy

    tttonyyy Active Member

    Messages:
    32
    Likes Received:
    38
    Joined:
    Mar 31, 2019
    Location:
    Southampton
    Your Mercedes:
    '03 ML270 (60k miles!)
    All back together and power is restored, harrah.

    However, there is a regular drip-drip-drip of fuel from the high pressure pump.

    Looks to be from the back of the pump where it joins the engine - possibly a shaft seal failure?

    Next on the list...
     
    Last edited: Apr 14, 2019
    Wighty and th3h1ghlander like this.
  16. th3h1ghlander

    th3h1ghlander Senior Member

    Messages:
    360
    Likes Received:
    92
    Joined:
    Mar 23, 2016
    Location:
    Chesham
    Your Mercedes:
    C-Class C270 CDI (W203)
    I took my HP pump off in 2016 and did a full seal replacement. I may still have some photos but I followed a guide with photos on the forum of some other chap doing it, was invaluable. I can dig out the photos if you think it is worth it?


    Sent from my iPhone using Tapatalk
     
    tttonyyy, Wighty and Blobcat like this.
  17. Wighty

    Wighty Senior Member

    Messages:
    5,710
    Likes Received:
    2,923
    Joined:
    Aug 4, 2016
    Location:
    Sunny Essex
    Your Mercedes:
    W211/E320cdi/2009 and CLK200k 2009
    Excellent pics and work buddy . As you say always useful for the next guy to learn from .
     
    tttonyyy likes this.
  18. OP
    tttonyyy

    tttonyyy Active Member

    Messages:
    32
    Likes Received:
    38
    Joined:
    Mar 31, 2019
    Location:
    Southampton
    Your Mercedes:
    '03 ML270 (60k miles!)
    Was it this guide?

    https://www.instructables.com/id/Universal-Bosch-Common-Rail-CP1-High-Pressure-Fuel/

    Doesn't look too bad though keeping it clean of dust might be bit of a problem (in our house just fitting screen protectors to phones without getting dust behind them seems to be a challenge). Maybe just thoroughly flushing with diesel/isopropyl will be enough in that regard. How did you manage it?

    This is the seal kit I've bought https://www.ebay.co.uk/itm/Seal-Rep...ssure-Fuel-Pumps-with-Front-Seal/123190094144

    At least this bit of the engine is easy to get to.
     
    th3h1ghlander likes this.
  19. th3h1ghlander

    th3h1ghlander Senior Member

    Messages:
    360
    Likes Received:
    92
    Joined:
    Mar 23, 2016
    Location:
    Chesham
    Your Mercedes:
    C-Class C270 CDI (W203)
    That wasn’t the fluid I followed but it does look good. Could be my imagination but that pump looks a little different?

    It wasn’t difficult although you will need a bench vice to undo the bolts on the outside of the pump (and an impact driver also helped). I have similar issues with dust and crap but wasn’t an issue, I took mine off outside in the driveway and did the pump seals in a dusty workshop, I was just careful.

    What spurned me to do mine is all in the post, but my leak in the cold weather was bad enough to not have enough pressure to start the engine.

    Here is a link to my post about the process, has parts and costs too for you to compare:

    https://forums.mbclub.co.uk/threads/fuel-pump-hp-renewal-c270-w203-borked-and-leaking.217409/

    Here is the guide I followed:
    https://forums.mercedesclub.org.uk/...diesel-injector-pump-seal-replacement.105316/

    While you have the pump off, check the hoses and seals that go to the pump and get a pack of spare seals for the hoses. May be best to buy a set of the hoses as I have been told the connectors are brittle and can break, mine were fine, but the hoses were expensive for what they were (OEM). Return the hoses if not used :)

    Hope that helps!



    Sent from my iPhone using Tapatalk
     
  20. OP
    tttonyyy

    tttonyyy Active Member

    Messages:
    32
    Likes Received:
    38
    Joined:
    Mar 31, 2019
    Location:
    Southampton
    Your Mercedes:
    '03 ML270 (60k miles!)
    That does help. Always useful to know things up front - like the fuel pipes being in the way of the bolts.

    Is all that clear fuel piping nylon? I've used nylon air line before to replace rotten fuel pipes between tanks and engines, though it's bit of a pain to get it hot enough to go over the fitting barbs.
     
    th3h1ghlander likes this.

Share This Page