2007 OM642 No boost, no DTCs, plenty replaced...
05-01-2018, 04:50 AM
#1
Newbie
Thread Starter
Join Date: May 2018
Posts: 1
Likes: 0
Received 0 Likes
on
0 Posts
2007 MB Vito 120CDI (W639 Extralang Mellitgelb)
2007 OM642 No boost, no DTCs, plenty replaced...
Hi all,
First of all, a small introduction; hi! I'm Niels from the Netherlands. Bought my W639 Vito van at about 224k kms late 2017, but it's been sitting in my garage for the last three months now with 228k kms with no power. It was converted to a camper van layout (Marco Polo style) in December, so I'd like to go enjoy it soon! I hope anyone can point me in the right direction here since I have quite some money and time invested in it:
Symptoms:
On the motorway I had full power as usual, I did a short burst from 60kmph to about 80kmph, and afterwards full throttle I could only maintain that 80kmph, but hardly accelerate anymore.
I noticed that the sound of the engine had changed as well. Kind of erratic air blowing noise, not hissing intake noise, but rather exhaust tone.
Car: WDF63960513312318 2007 Vito 120CDI Extralang
Diagnosed using a iCarsoft MB2 scanner produced three DTCs:
Glow plug #5
y77/1 turbo actuator
Intake flaps.
Repairs executed (all done myself, using WIS):
1st round:
Before troubles at 225k engine oil and ATF replaced
Swirl flap motor deleted and resistor mod performed -> DTC gone
PCV valve replaced with current partno (as precaution)
Hella turboactuator overhauled and checked professionally and checked -> DTC gone
Replaced all glow plugs -> DTC gone
Replaced fuel filter (when I was in the neighborhood)
Charge pipe O-rings replaced
TransGo 722.6 shift kit installed in trans (is has the shudders)
Went for a drive: still the same noise and no boost. No DTCs anymore.
More symptoms after more careful examination from beneath:
Right exhaust manifold was leaking badly, one hole in the piping and in the flexi part. This could explain the noise and pressure loss, and the turbo could have been damaged by the debris.
2nd round:
Both exhaust manifolds left and right replaced with non-OEM single wall stainless units.
Turbo replaced with Garrett upgraded stage 1 hybrid (upgraded bearings and billet higher flow compessorwheel), switched the overhauled actuator over to this turbo. The turbo housing itself is the same model/size etc, just has upgraded internals.
Went for a drive yesterday: No more noise, still no boost, and no DTCs on the diagnostics.
My thoughts for proceeding:
I can see the y77/1 turbo actuator moving a full motion upon startup, but I suspect it does not move and thus creating boost when applying throttle (->still to check). The cause of this might be the EGR pressure sensor, MAP, MAF sensor? Could the EGR valve stuck open cause this? This is where I'm not so sure where to look, any thoughts?
If you've made it reading this so far: thanks in advance!
Best regards, Niels
First of all, a small introduction; hi! I'm Niels from the Netherlands. Bought my W639 Vito van at about 224k kms late 2017, but it's been sitting in my garage for the last three months now with 228k kms with no power. It was converted to a camper van layout (Marco Polo style) in December, so I'd like to go enjoy it soon! I hope anyone can point me in the right direction here since I have quite some money and time invested in it:
Symptoms:
On the motorway I had full power as usual, I did a short burst from 60kmph to about 80kmph, and afterwards full throttle I could only maintain that 80kmph, but hardly accelerate anymore.
I noticed that the sound of the engine had changed as well. Kind of erratic air blowing noise, not hissing intake noise, but rather exhaust tone.
Car: WDF63960513312318 2007 Vito 120CDI Extralang
Diagnosed using a iCarsoft MB2 scanner produced three DTCs:
Glow plug #5
y77/1 turbo actuator
Intake flaps.
Repairs executed (all done myself, using WIS):
1st round:
Before troubles at 225k engine oil and ATF replaced
Swirl flap motor deleted and resistor mod performed -> DTC gone
PCV valve replaced with current partno (as precaution)
Hella turboactuator overhauled and checked professionally and checked -> DTC gone
Replaced all glow plugs -> DTC gone
Replaced fuel filter (when I was in the neighborhood)
Charge pipe O-rings replaced
TransGo 722.6 shift kit installed in trans (is has the shudders)
Went for a drive: still the same noise and no boost. No DTCs anymore.
More symptoms after more careful examination from beneath:
Right exhaust manifold was leaking badly, one hole in the piping and in the flexi part. This could explain the noise and pressure loss, and the turbo could have been damaged by the debris.
2nd round:
Both exhaust manifolds left and right replaced with non-OEM single wall stainless units.
Turbo replaced with Garrett upgraded stage 1 hybrid (upgraded bearings and billet higher flow compessorwheel), switched the overhauled actuator over to this turbo. The turbo housing itself is the same model/size etc, just has upgraded internals.
Went for a drive yesterday: No more noise, still no boost, and no DTCs on the diagnostics.
My thoughts for proceeding:
I can see the y77/1 turbo actuator moving a full motion upon startup, but I suspect it does not move and thus creating boost when applying throttle (->still to check). The cause of this might be the EGR pressure sensor, MAP, MAF sensor? Could the EGR valve stuck open cause this? This is where I'm not so sure where to look, any thoughts?
If you've made it reading this so far: thanks in advance!
Best regards, Niels
Last edited by Nelis; 05-01-2018 at 04:57 AM.
05-22-2023, 02:12 AM
#2
Newbie
Join Date: May 2023
Posts: 1
Likes: 0
Received 0 Likes
on
0 Posts
W639 Vito 115
W639 turbo replaced oil feed bolt not aligning
Hi Nelis. My name is Colin from South Africa. I Recently replaced my turbo with a non OEM part and got stuck with an alignment issue on the oil feed bolt. Approx 2mm short on the same axis as the oil feed pipe. Would you be able to advise if there is a fix for this problem? Kind regards.
05-22-2023, 11:19 AM
#3
MBWorld Fanatic!
Join Date: Jan 2009
Location: V E G A S
Posts: 9,067
Received 1,730 Likes
on
1,380 Posts
1922 Ford Model T / no OBD
What engine is that?
You deleted swirl flap motor, when flaps likely were frozen by gunk.
It is like putting black tape over CEL.
You deleted the results, without addressing the issue.
You deleted swirl flap motor, when flaps likely were frozen by gunk.
It is like putting black tape over CEL.
You deleted the results, without addressing the issue.
The following users liked this post:
rapidoxidation (05-23-2023)
