OH MAN!! I'm glad I took the cover and foam off so I could smell it way before that happened. You can change all the injector seals in your drive way with a nice Saturday afternoon and some patients. Just take your time cleaning it up.

 

Yeah good call on removing them. I figured they didn’t serve much purpose but didn’t realize their presence could lead to such a mess
Off to the dealer soon in limp mode for parts. Gonna need to get this crap hot to remove the injector

 

10 hrs into this mess. About 3 more hours of removing crud then time to reassemble.
Turns out it was both sides

6 washers, orings and bolts were 57ish CAD after tax at Mercedes dealer so not bad for same day parts. The orings are 3 times more then the bolts ($1.50 vs 4.50 each) ???

One injector has a bulged tip... a little concerned just trying to decide if I wanna pretend I didn’t see it.

And some more pics...

 

I soaked my dirty one in fuel injector cleaner, wiping it off occasionally. Worked good with no scrubbing while I cleaned up the injector hole.
Be careful torquing the hold down bolts. They do not require much torque and are a torque to yield bolt, so it will stretch some. I think it was only like 60in-lb if I remember correct. Use a manual scale or a good digital wrench incase you do not hear the click like I did and break the bolt down in the head.

 

I used a twist handle torque wrench, seemed to work well. 60 in/lbs plus 1/4 turn with a ratchet.

Speaking of injector hole. Did anyone else make sure all the openings in the injectors were clean? I soaked them in Super Clean for hours and the cleaner was jet black. Then to double check I took a piece of stainless wire from a wire brush and lightly checked for crud in the gap where fuel comes out. Turns out 5 out of 6 “looked” clean from the outside but the gap had really hard crud that had to be scraped out. This added a couple hours to the job, in hindsight it may have been better to either let them soak overnight, or use an ultrasonic cleaner. The stuff was rock hard in places.
When clean the wire should go straight down along the nozzle and bottom out at around 6.2mm. Maybe a diesel expert could verify it looks and feels as though the “bottom” is just a machined shoulder on the nozzle so be nice but not delicate as there really isn’t anything to damage going straight down along the nozzle

As it was the weekend I couldn’t find any injector shops open to test them. It’s all back together now and for the first time since getting a tune I saw under 10 l/100km on the highway. Actually 8.2l/100.

It has smelled like exhaust since getting tuned 2 years ago. Aside from a touch of residual smell it’s like a new car :smile2: