Ml w163 270 - egr - pipes - manifold - cleaning

[Sudesh]

This is as clean as I could get the manifold, hard to see in the pics but its a big improvement.








Huge amount of crud came out after the steam clean, but its pretty much impossible to get it all. Still pleased with the results when you compare it to this:

[Sudesh]

While everything was out I decided to replace the thermostat.

Its located here on 2003 ML 270CDI, three bolts hold it in place
and unplug the sensor.



With the housing removed you can now see the stat.



remove the little bar as the stat needs to be twisted to get it out.

[Sudesh]

More to follow tomorrow.

[Sudesh]

Originally Posted by dokalj

Hi Sudesh,

Where is the oil seperator? I think I read someone changed theres and it cured the response.

Will you be changing the gaskets at the same time?

dokalj

Hi,

This is where the oil separator is, just 4 bolts from memory and it comes out easy enough, just unplug the tube running into it, the seal is just along the inside edge, replace this also. I'll have pics tomorrow hopefully but this will give you an idea where it is:

[Sudesh]

So I learned today the thermostat comes as a complete unit from mercedes, so here it is, seal and all.



While installing everything again, I noticed the seal around the EGR pipe or boost pipe as Merceds call it was a little loose and out of shape, it just would not sit in tight, so I got a new one as I wanted everything to be correct, and surpris, surprise, they said it comes complete, so new pipe and seal:



Old pipe where seal wont seat corectly




New pipe:





This is the old oils separator, this more than likely could be cleaned down, but its not too expensive so I just ordered a new one and new seal. Hopefully will arrive later today or tomorrow.

[gtvlusso]

Thats some good work Sudesh!

Can you put up a list of part numbers and seal sets for what you have serviced? I have a 2002 ML 270 CDI and it coupld probably benefit from the same treatment!

[dokalj]

Nice job Sudesh!

What are the advantages to changing the oil seperator?

Also could you please to tell me the part numbers for the oil seperator and boost pipe with the associated costs?

Does your vehicle lack performance? Is this why you decided to clean it all up?

Regards

dokalj

[Sudesh]

Originally Posted by gtvlusso

Thats some good work Sudesh!

Can you put up a list of part numbers and seal sets for what you have serviced? I have a 2002 ML 270 CDI and it coupld probably benefit from the same treatment!

Hi,

Yeah I will try my best! Havent got all the receipts through yet.

Originally Posted by dokalj

Nice job Sudesh!

What are the advantages to changing the oil seperator?

Also could you please to tell me the part numbers for the oil seperator and boost pipe with the associated costs?

Does your vehicle lack performance? Is this why you decided to clean it all up?

Regards

dokalj

Hi,

To be honest, I have not driven another 270 CDI so have nothing to compare it performance wise, but yes that is one of the reasons I done it to see if there is ANY difference; maybe there wont be, but at least its done now and piece of mind for a while. Another reason for the clean down of manifold, EGR etc is, I found it a little smoky under load, nothing overly bad but just wanted to do it anyway, also I find it a tad sore on fuel so hopefully I will find some difference when I get to testing it tomorrow all being well, just waiting for some parts to arrive.

The thermostat was also on its way out, the readings were low at times when driving and if I stated the ML in the mornings and left it to idle, the gauge would not move at all until I accelerated.

As for the oils separator, have a look here, its not ML specific but not a bad read.

[Sudesh]

While waiting for some parts to arrive, I took to doing some cleaning and installing the new air filter. There some small traces of oil in the filter ox inlet as far as the mesh.

Filter lid


Inside


I removed the inlet port to get at the mesh better, not really needed to be removed but I wanted to get at it correctly.





You can see the oil here:


So after a good cleaning with EGR cleaner it came up nicely and no oil residue.




Sensor also cleaned down, was in good condition anyway.

[Sudesh]

When I asked a MERC TECH about the turbo/intercooler damper, he wasnt very forth coming lol, he just said there will be a bit of oil in there and if I wanted to clean it, it wouldnt do any harm, and basically said, if you buy a new one its dry!!

So I took to cleaning that out too, there was some oil that seeped out of the little holes inside, so I filled a spray bottle with paraffin and started spraying inside, as I done this more oil seeped out, so I just kept going till it all ran clear. I then left it to dry for a while and heres some pics of it cleaned out.




It pretty much dried out now, but I'm going to leave in the boiler house over nite to give it an extra drying session.

I have also cleaned out the pipes that attach to this and intercooler.

[dokalj]

Great Work.....Your ML will run like new

Are you going to look at the cats?

Regards

dokalj

[gatty]

Sudesh

out of interest are you using a 'Tuning Box/chip', thought i could see one in thread 11, picture 2.

If so do you think this contributes to build up of gunk/smoke.

[Sudesh]

Originally Posted by gatty

Sudesh

out of interest are you using a 'Tuning Box/chip', thought i could see one in thread 11, picture 2.

If so do you think this contributes to build up of gunk/smoke.

Hi,

Yes I did buy one, I dont believe its the cause of this build up as I have only just installed it a day or two before doing this service work. The build up is fairly common on most modern diesels I believe. I have done the same clean out on BMW' Fords and Peugeot, All of which ran complete different when it was done, there was improved MPG and performance plus no smoke.

[dokalj]

Is this correct Sudesh?

Oil Separator A613 188 01 01, £141.48 incl vat.

Not exactly cheap IMHO.

Or is this the wrong part number?

Regards

dokalj

[dokalj]

In post 11, picture 1.

There is a white clip connecting a rigid fuel line (from the common rail) to a flexible fuel line, could you please measure the two diameters becuase I have been after this part for a long time and Mercedes Germany say they need it to proceed asap.

Im not with my car atm, so it will be like later on in the week.

I just thought seeing as you have the car apart, you may agree. If not I totally understand.

Thanks for the great write up so far.

Regards

dokalj