C320CDI

Hi Guys, my OM642 is giving me uphill.
Some background to my question, I got the Turbo overhauled in April 2019. Came back beautiful and everything working 100%

Now this week car goes into limp with error code P0244 and P2510. I check the wiring inside the actuator no problem, I have another actuator and swop that out and still no go. See the link below for the video.

Do any of you guys had this? I checked fuses, all looks fine. What am I to do next?

Any help into the right direction I will appreciate.

https://drive.google.com/open?id=1-LYfm3T5SdDU-nPX4kYMM94dcV4xvlxR

artim808

What is wrong on the actuator you showed on video? I believe it is doing what is supposed to do once you start the car.

kajtek1

What's the mileage on the engine and why you had turbo rebuild?
The main issue with the flap system is semi-hard build-up around them, what can
-break control rod
-burn the actuator
-freeze whole system.
So if you have high-mileage engine, cleaning the build up is required maintenance.
Dealers replace manifold with new one, what can get pretty expensive, but that is nice DIY job with no cost to the owner.

C320CDI

The Actuator needs to stay down till you excellerate. When the actuator flips up the tone of the exhaust also change to a deep tone and the mil lights up.

The milage is 189000kms. The turbo shaft was leaking oil, so I had to replace the Turbo Core and vaines.

C320CDI

I cleaned the manifolds last year in Feb when I replaced the swirl flap/ stepper motor.

kajtek1

So now, after we gather basic information, we can analyze the codes.
P0244 MERCEDES-BENZ - Turbocharger/Supercharger Wastegate Solenoid 'A' Range/Performance
P2510 The Powertrain Control Module (PCM)/Engine Control Module (ECM) monitors the voltage to the ECM/PCM Power Relay. The ECM/PCM set the OBDII code set when the ECM/PCM Power Relay is out of factory specifications
The first code suggest bad turbo performance. It can be leak in the intercooler system, or bad turbo, so start with checking for leaks
The 2nd code indicate electric or electronic problem. Clean all the plugs going to engine computers with MAF or other cleaner and if that doesn't help, you might need better scanner to go farther.

C320CDI

Thanks kajtek1, I will start checking

C320CDI

OK, I test for leaks on intercooler and pipes -- No leaks.
Tested the wiring -- no problems

So I got this brain fart -- I took the arm of the turbo vaines of the actuator. Pulled the arm up to start the car and after start let it drop back. And guess what. The actuator stays down and no mil. I tried pulling the vaines arm up to feel the movement and boy was that a stepping movement. So it looks definitely like the "new" vaines is shot. 4 months old? What can be the cause of this? Heat that makes the vaines melt around the edges?

kajtek1

I was rebuilding my turbo at 180k by pushing new bearing sleeve and some small parts and veins, although they had some soot to clean did not need rebuilding.
I think something went wrong with your rebuild.

C320CDI

I found the problem. A piece of the metal pipe inside the exhaust manifold came loose and came thru the Turbo. Now the question is how on earth do I get this loose metal pipe out of the exhaust manifold?

I googled myself blue in the face looking for help how to remove the exhaust manifold on the left-hand side of the car.

Does anybody have a manual or pics of how to remove the left side exhaust manifold? I'm driving a W203 with a om642 engine and the space around the engine is not enough to swing spanners around.

🥺

kajtek1

Picture would be great help.
I can't even imagine what you are talking about.

C320CDI

Hi Kajtek1, see the pic's. The triangular flange is the end of the flexible exhaust manifold. The pipe inside that flexible manifold is what I need to remove.

The other picture is showing the heat shield over the exhaust manifold that I need help with to get it removed, so I can get the manifold off the engine.

The Triangular flange at the end of the flexible exhaust manifold


Heat shield over exhaust manifold

Towmater

Attached is the breakdown from wis

C320CDI

Kajtek1, this breakdown is excellent. Thank you so much. I managed to remove the left side manifold. I will remove the right side tomorrow. Thank you Kajtek1, you are really a blessing.

Where can I source a pdf manual for the OM642 engine. I've tried downloading manuals for the W203 in om642 but no luck.

But Thank you again you were really helpful.👌

Towmater

Lol posted by towmater, but ok. You can sometimes find stuff on ebay, stuff about the same engine in sprinters or just buy access to wis when you need it at $60 a day.