The insurance assessors wrote the vehicle off. The repair is still going strong after a couple years I managed to T-BONE a clown who jumped the stop street and give the front half of my van fat hair lip. lapped in the seat face and put it all together using the thicker HONDA washer what a pleasure. I decided that it was pointless going back and carried out the repair myself.I bought the bolt the OEM copper washers and the Honda washers. No we pull the injector out slip a new washer in and and that’s it, repair complete. I quizzed the forman regarding replacement of the shrink bolt. I phoned the garage that carried out the repair and was told bring it back your repair has a 1 year guarantee. The lapping in of the injector seat face The suggested replacement of the copper washer with the Honda 2.2 Accord. The replacement of the shrink bolt and cleaning out the bolt threads and debris blown out of the threaded bolt holes to make sure the bolt bottomed out when torqued down. Scouring through Google for DIY answers to black death, I came across Mercedes Gen-in and Mr Steve Ball. They failed miserably.The repair lasted just three months. I took the vehicle to a recognised MB repair shop. It started chuffing and resulted in black death. Hi Steve I have a Vito CDI 115 2004 panel van. They look slightly thicker and are definitely made from a softer more malleable material than the OEM Mercedes units – My own view is that this ‘softness’ assists in sealing to irregular hand cut/cleaned seal faces and seats better than the harder MB equivalent washers. I have photographed the Honda part (injector seal) above in its original packet for ease of identification and obtaining the part should you wish to use the alternative copper sealing washer. Also interesting testament to chipped and tuned engines and their longevity, this one was performance chipped from new and at half a million miles running its hard to say that it has in any way been detrimental to its life span – an interesting point of note. So now all seals have been replaced with Honda parts and the van is once more good-to-go! This engine, along with the van itself has covered over 500,000 hard courier miles and although the piston rings/bores are now nearing end of life (increased crank case pressure) it still sounds sweet and runs like a train. ![]() Laser 4597 Diesel Injector Seat Cutter Set I knew this seat was good last time I replaced the seal so there had been a problem with blow by gasses cutting the seating face. The seat was recut then lightly faced with a hand reamer / face cutter tool then checked with a mirror and torch. On removal of the injector ( slacken injector hold down clamp bolt and run engine to normal operating temperature – this often unseats the injector allowing relatively trouble free removal) It was discovered the seat was scored and pitted. Previously the other 3 injector seals in this engine had been replaced with Honda types and this single remaining one (No.2 Cylinder) was an original Mercedes OEM seal installed at the same time as the others, simply because I had no more Honda parts available. Unlike most common ‘Black Death’ related failures this one had just decided to spray diesel everywhere under the bonnet without any prior warning or over-time buildup of coke around the injector. I had one of the courier fleets T1N 4 metre Sprinters in for repair due to a chuffing injector.
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