Rotting Intake Plenum
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Junior Member
Joined: Jul 2007
Posts: 65
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From: alabama
1997 mercedes e300d
Rotting Intake Plenum
My check engine light has been staying on and I took it to the shop. I was told that air is getting into the intake plenum from outside the intake. Unpon inspection, the intake plenum appears to be rotting, pitted, corroded, etc. The mechanic put silicone around the edges to prevent excess air, but the light still stays on.
Searching the internet, I did not find anything, but the mechanic has talked to other mechanics around the country and he has heard that this is not the first time. This is close to a $2,000 repair and from a faulty part. The car has not seen salty air and has spend most of it's life in Arizona, now in Alabama.
One would think that Mercedes would honor a replacement for a faulty manufactured part, but MBUSA won't even respond to inquiries. I do know a Mercedes engineer who works at the Mercedes Plant in Vance, AL, but I am very surprised that a part would just rot. I'd understand if the car were around road salts or in a salty air climate, but it has been in an arrid climate for 70,000 miles until I bought the car.
Any suggestions or advice would be appreciated.
Searching the internet, I did not find anything, but the mechanic has talked to other mechanics around the country and he has heard that this is not the first time. This is close to a $2,000 repair and from a faulty part. The car has not seen salty air and has spend most of it's life in Arizona, now in Alabama.
One would think that Mercedes would honor a replacement for a faulty manufactured part, but MBUSA won't even respond to inquiries. I do know a Mercedes engineer who works at the Mercedes Plant in Vance, AL, but I am very surprised that a part would just rot. I'd understand if the car were around road salts or in a salty air climate, but it has been in an arrid climate for 70,000 miles until I bought the car.
Any suggestions or advice would be appreciated.
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Joined: Jan 2007
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From: Sydney, Australia
190D 2.5 (x2), 190E 2.6, W202 C240,W202 C43 (C55), W210 E55, W212 E250CDI
What's the fault codes/symptoms you're having?
I doubt the manifold has rotted, it's cast alloy, it has a rough appearence.
Any pics you could post?
I doubt the manifold has rotted, it's cast alloy, it has a rough appearence.
Any pics you could post?
Junior Member
Joined: Nov 2009
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ML63, VW Jetta, STI, Ducati Monster 1100
I am in the same boat as you. Mechanics have narrowed it down to air getting into the intake manifold. They don’t know if it’s from the Intake manifold runner butterfly flaps or from the gasket mount areas. ML63 fix is 3300.00. New manifold is about 2800.00 plus labour. Unsure where I should go from here.
MBWorld Fanatic!
Joined: Jan 2007
Posts: 1,152
Likes: 29
From: Sydney, Australia
190D 2.5 (x2), 190E 2.6, W202 C240,W202 C43 (C55), W210 E55, W212 E250CDI
For your ML63 that's a compleately different issue.
Diesels can run with no intake manifold fitted at all which is why I'm quetioning the "air leak theory"
Best place to start on a 63 is the intake manifold gaskets, very common. very few actually leak from the variable runner shaft but it's very easy to check.
Diesels can run with no intake manifold fitted at all which is why I'm quetioning the "air leak theory"
Best place to start on a 63 is the intake manifold gaskets, very common. very few actually leak from the variable runner shaft but it's very easy to check.
Junior Member
Joined: Nov 2009
Posts: 43
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ML63, VW Jetta, STI, Ducati Monster 1100
For your ML63 that's a compleately different issue.
Diesels can run with no intake manifold fitted at all which is why I'm quetioning the "air leak theory"
Best place to start on a 63 is the intake manifold gaskets, very common. very few actually leak from the variable runner shaft but it's very easy to check.
Diesels can run with no intake manifold fitted at all which is why I'm quetioning the "air leak theory"
Best place to start on a 63 is the intake manifold gaskets, very common. very few actually leak from the variable runner shaft but it's very easy to check.
Junior Member
Joined: Nov 2009
Posts: 43
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ML63, VW Jetta, STI, Ducati Monster 1100
Ausnmtech, thanks again for your comment towards my post. It got me thinking and I proceeded to investigate more based on my thoughts and not what the mechanic told me. It seemed too easy to say intake 3300 done!
So after about 45minutes I discovered my problem, part number A 1560180282 “HOSE AT TIMING CASE” was cracked almost its entirety. No part available locally so I have it ordered. In the mean time duct tape and all is good for now and my bank account is happy too!
So after about 45minutes I discovered my problem, part number A 1560180282 “HOSE AT TIMING CASE” was cracked almost its entirety. No part available locally so I have it ordered. In the mean time duct tape and all is good for now and my bank account is happy too!
Thread Starter
Junior Member
Joined: Jul 2007
Posts: 65
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From: alabama
1997 mercedes e300d
The intake plenum, was leaking air and throwing a code that the fuel/air was out of kilter. The Check engine light stays on all the time. The car is now making a very loud obnoxious whistle. I took the car to the Mercedes Plant in Vance, AL. I have a friend there that I went to college with who is an engineer. They took apart the car and sure enough, a pitted and corroded part. I will post pictures once I get to the dealer in Tuscaloosa. The engineers said the part is not a Mercedes part, but outsourced. I finally spoke with a girl at MBUSA, who said the car was likely washed with some engine solvent that has caused the metal to rot. The engineers said that is not possible, the surrounding metal or alloy would have the same problem if that were the case. It was found to be a defective metal. MBUSA still requires me to go to the local dealership (WILL NEVER go to the one in Birmingham, been "Crowned" once) to verify, but said they would most likely discount the part since the car is 12 years old.
Personally, I don't think ANY part on the car should rot, especially since the car has not been around corrosive liquids as far as I know. A little help is better than none, but if the part is defective, it should be replaced at no cost to me. Just sayin...
Personally, I don't think ANY part on the car should rot, especially since the car has not been around corrosive liquids as far as I know. A little help is better than none, but if the part is defective, it should be replaced at no cost to me. Just sayin...
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MBWorld Fanatic!
Joined: Sep 2005
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From: Albuquerque
'10 CL550, '12 GL550
Defective parts are indeed replaced under warranty.
The only promise you'll ever get from Mercedes is the original warranty term, or possibly an extension for a CPO car ... another warranty for which you pay.
The ONLY parts on ANY car ANYWHERE that are warranted for life are warranted because it's government required and those are strictly parts that affect safety and emissions. Emissions parts covered are specifically listed and your part needs to be on the list.
There's no such thing as lifetime warranty for things that "shouldn't happen." Nowhere.
Even non CPO Mercedes purchased at a Mercedes dealer have a paper in the window stating "as is" and that's what it is.
Closest you can come to getting after-warranty replacement is when you've bought the car new and religiously had it serviced at that same dealer and you approach that same dealer for "good will." It will be the dealer and not Mercedes that helps you.
Your expectations are unrealistic.
The only promise you'll ever get from Mercedes is the original warranty term, or possibly an extension for a CPO car ... another warranty for which you pay.
The ONLY parts on ANY car ANYWHERE that are warranted for life are warranted because it's government required and those are strictly parts that affect safety and emissions. Emissions parts covered are specifically listed and your part needs to be on the list.
There's no such thing as lifetime warranty for things that "shouldn't happen." Nowhere.
Even non CPO Mercedes purchased at a Mercedes dealer have a paper in the window stating "as is" and that's what it is.
Closest you can come to getting after-warranty replacement is when you've bought the car new and religiously had it serviced at that same dealer and you approach that same dealer for "good will." It will be the dealer and not Mercedes that helps you.
Your expectations are unrealistic.
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