Vito 120 CDI problems.

[old builder]

Hello all.
New to the forum. Seeking advice on a 2008 Vito 120 cdi. That is the 3 litre V6 engine. Owned from new, 160k miles. Been in limp mode for a while and has now given up the ghost completely. Came to a stuttering halt and had to be recovered. Local mechanic read a number of faults on it but had no interest in doing any work on it. EGR valve seems a favourite subject when advice has been sought.
What I really need is a workshop manual for the engine. Does anyone know where I can obtain one please? Happy to pay or download but essential for me to be able to work on it my self.
Mike

 

[mattkh]

Does the engine turn over?
What are you going to tackle first?

 

[old builder]

Does the engine turn over?
What are you going to tackle first?

Hello Mattkh
Yes engine cranks ok and tries to start. The opinion of a Merc mechanic is that is likely to be EGR related, possibly seized, so that is where I will start. Experienced enough to work on it myself but really need a manual to guide me on procedure and location of items. Very difficuly access because it is a van, even getting engine covers off is a nightmare. Thanks for your interest.
Mike

 

[mattkh]

The videos on utube are very helpful.
If there isnt one for your motor, look at one for another car. It will give you an idea of whats involved. There is one for a Hyundai Santa FE with a water cooled EGR.
Please put up a picture, a birds eye view, of the engine, and tell me the engine code.
Here's a link to what they look like

2015 MERCEDES BENZ E CLASS W212 E350 CDI V6 EGR VALVE A6421402560 | eBay

REMOVED FROM A 2015 E350 CDI. -FOR GEARBOX WARRANTY WILL ONLY BE COVERED IF OIL HAS BEEN CHANGED TO NEW AND FILTER(IF APPLICABLE). IN GOOD WORKING ORDER. -FOR ENGINES WARRANTY WILL ONLY BE COVERED IF TIMING CHAIN/BELT HAS BEEN REPLACED ALONG WITH NEW OIL/FILTER.

www.ebay.co.uk

 

[old builder]

Thanks Mattkh.
I have been looking on youtube myself, couple on there re v6 mercs but cars not vans. Reasonably easy on a car but on a Vito you can't even see the thing as it is buried behind the turbo. Maybe have to be accessed from below as there is very limited access from the front and none from the top as the engine sits back under the dash. I will take a photo and post it up as soon as I can. Thanks.
Mike

 

[mattkh]

Thanks. Now I know where the engine is, there is no need for the photograph. Looks like you may have to remove the turbo to get to it.
What is the engine code please.

 

[Ivan Mihov]

Hello mate, sometime THE Blocked DPF can make EGR to have fun .I will point that first. Disconnect the DPF from a turbo. then check the turbo it is a wastegate OK, then disconnect the hose from inter cooler to the EGR and whit mirror and light torch have a visual inspection. All this can be figured out whit good scanning tool as well and someone who can work whit it

 

[M80]

I had my EGR seize on a 2009 Viano OM642. It went into limp, but would restart easily.
I'm surprised yours wont.

Mine was easy to get to sitting on the top of the engine at the front,
one like this

EGR GAS RECIRCULATION VALVE ENT500147 ENGITECH I | eBay

Find many great new & used options and get the best deals for EGR GAS RECIRCULATION VALVE ENT500147 ENGITECH I at the best online prices at eBay! Free delivery for many products.

www.ebay.co.uk

Is it possible your EGR was causing limp but now you have an additional issue that is preventing the start?

Btw, I bought a new EGR from Lithuania but after much soaking in plus gas and manipulation the carbon shifted and the old one sits in the garage working freely again. I think it's worth removing these annually for a clean up.

 

[old builder]

Thanks. Now I know where the engine is, there is no need for the photograph. Looks like you may have to remove the turbo to get to it.
What is the engine code please.

Thanks Mattkh,
I will try to have a look today. Do you know where the code may be?
Mike

 

[old builder]

I had my EGR seize on a 2009 Viano OM642. It went into limp, but would restart easily.
I'm surprised yours wont.

Mine was easy to get to sitting on the top of the engine at the front,
one like this

EGR GAS RECIRCULATION VALVE ENT500147 ENGITECH I | eBay

Find many great new & used options and get the best deals for EGR GAS RECIRCULATION VALVE ENT500147 ENGITECH I at the best online prices at eBay! Free delivery for many products.

www.ebay.co.uk

Is it possible your EGR was causing limp but now you have an additional issue that is preventing the start?

Btw, I bought a new EGR from Lithuania but after much soaking in plus gas and manipulation the carbon shifted and the old one sits in the garage working freely again. I think it's worth removing these annually for a clean up.

Hello M80.
Thanks for your help, I think you may be right about more than one problem. One of the fault codes said pressure sensor. Having had trouble with wiring loom before, chaffing on a bracket and wearing through, I intend to try and give the wiring a good check over.
Mike

 

[old builder]

Hello mate, sometime THE Blocked DPF can make EGR to have fun .I will point that first. Disconnect the DPF from a turbo. then check the turbo it is a wastegate OK, then disconnect the hose from inter cooler to the EGR and whit mirror and light torch have a visual inspection. All this can be figured out whit good scanning tool as well and someone who can work whit it

Thanks for your help Ivan.
Some good tips there. Problem with the Vito 120 is that access is extremely difficult but I will keep working at it.
Mike

 

[mattkh]

The engine code should be on the sticker on the B pillar.
On the cable chaffing, just do a continuity test with a multimeter.

 

[M80]

Hello M80.
Thanks for your help, I think you may be right about more than one problem. One of the fault codes said pressure sensor. Having had trouble with wiring loom before, chaffing on a bracket and wearing through, I intend to try and give the wiring a good check over.
Mike

Careful with the meter probes.
On some connectors pushing the probes in to test can flare them and then they have an unreliable connection at the sensor.

 

[old builder]

The engine code should be on the sticker on the B pillar.
On the cable chaffing, just do a continuity test with a multimeter.

Hello Mattkh.
Nothing to be found about engine type anyware I can find but on the cam cover it has A 642 0101630 cast in if that helps. I think I have been misled on where to find the AGR. I am pretty sure it on the front left of the engine tucked down fairly low. That would tie in with where M80 found his. I have ordered a Endiscope so that I can look around things better. On wiring problems, I found before wiring that had rubbed through the protector sleeve and insulation causing intermittent short circuiting of various sensor signals I suppose. Cost me £1500 with a so called specialist replacing various parts until I found that myself. That's why I am very wary of them now.
Mike

 

[mattkh]

Thanks.
My research points to a brand new design of an engine, an aluminium one. Can you look up please the log book. The engine code is shown there as well.

 

[M80]

Are there significant differences between OM642 engines of a different code, in their physical construction that is.

But you engine code can be derived from the VIN. This will start WDF639 and typically found on the passenger B pillar.
Enter that into a VIN decoder

Mercedes VIN Decoder | Decode Your Mercedes-Benz VIN

Want to know the specifications of your Mercedes? No problem! Our free Mercedes VIN decoder retrieves detailed information about your Mercedes-Benz vehicle.

www.lastvin.com

That'll provide your engine code and a lot more.

 

[M80]

I would suggest you need a good Merc Indie.
Put up your location and recommends will be forthcoming.

You need the codes to understand what is inhibiting the start.
You may be lucky to get some direction from a cheaper code reader, and if time isn;t desperate it could be a starting point.
Otherwise this wants to go on Star / Xsentry.

So far it sounds like you're floundering some and these can become more complicated as you dig in.

For example w/o the full wiring detail showing wire colours and terminal numbers your identifying poor connection / shorts is unlikely.
I spent days testing out from the ECU to sensors. Actually it was that that showed poor connection to 3 components due to previous sensor connections being flared.
Then if you aren't aware of what readings to expect from seniors the red herrings will be numerous, more difficult at this time of year, for me it was summer.

I would be amazed if your engine isn't the same as my previous 2009 engine, aside from perhaps power output.
I have much info as I keep records.

 

[old builder]

I would suggest you need a good Merc Indie.
Put up your location and recommends will be forthcoming.

You need the codes to understand what is inhibiting the start.
You may be lucky to get some direction from a cheaper code reader, and if time isn;t desperate it could be a starting point.
Otherwise this wants to go on Star / Xsentry.

So far it sounds like you're floundering some and these can become more complicated as you dig in.

For example w/o the full wiring detail showing wire colours and terminal numbers your identifying poor connection / shorts is unlikely.
I spent days testing out from the ECU to sensors. Actually it was that that showed poor connection to 3 components due to previous sensor connections being flared.
Then if you aren't aware of what readings to expect from seniors the red herrings will be numerous, more difficult at this time of year, for me it was summer.

I would be amazed if your engine isn't the same as my previous 2009 engine, aside from perhaps power output.
I have much info as I keep records.

Floundering may be right but I am in no hurry so have not really had a serious go at it yet. I don't trust local so called specialists, they rely to much on what the computer says without thinking why. I am in Crediton Devon EX17 6BE. If there was a local Merc indie about, I would be keen to use them. I will get the VIN number and engine details.
Thanks all, much appreciated.
Mike

 

[mattkh]

Hello Mattkh.
Nothing to be found about engine type anyware I can find but on the cam cover it has A 642 0101630 cast in if that helps. Mike

Thanks.
That cam cover number has cracked it. The 642 in the number is your engine code. So it is a OM642.
My research led me up the wrong number. Your engine is not an aluminium block.

 

[mattkh]

Mike

Have you seen this video. The EGR is to the right of the turbo.