More specifically, a ‘dull plopping noise from the intake manifold – when the air filter is removed’. In our case, all the time – the customer had complained for a little while that the engine was noisy. It sounded a bit odd but there wasn’t anything specific that we could say at that point. Until it got worse and it was at the point that it needed stripping and investigating. Booking confirmed; first and foremost, checking Mercedes Benz TIPS system show that we wasn’t the first…
Anyway MB on the OM654 engine;
“The new four-cylinder diesel unit OM 654 marks the debut of a ground-breaking family of engines from Mercedes-Benz. Exemplary efficiency and emissions ensure that the premium diesel is future-proof while underlining the key role to be played by the diesel engine in achieving the challenging global climate targets. The first all-aluminium four-cylinder diesel engine from Mercedes-Benz celebrated its world premiere in the new E-Class E 220 d in spring 2016.” (Read more here).
Fast forward to 2021 and we have the ‘dull plopping noise from intake area – that i feel may become more and more common, therefore needing the repair as we had.
GI05.30-P-070181 is TIPS document that gives us the info we need;
Complaint
Rough idling and a dull plopping noise is heard from the clean air line when the air filter is removed.
The engine indicator lamp may also be active.
Cause
Wear of the roller-type rocker arm on the exhaust side
Remedy
Remove roller-type rocker arm and check for wear. Wear is indicated by increased radial play in the needle bearing. Replace the following component parts:
– all roller-type rocker arms
– all compensating elements
Replace the following component parts if required:
– Camshafts / camshaft bearing housings
After completing the repair, change the engine oil and oil filter.
If the engine indicator lamp is also active and fault code P0101FA occurs, contact your market support for more detailed instructions.
Notes:
Wear-optimized roller-type rocker arm A 654 050 66 01
Wear-optimized compensating element A 642 050 02 80
When removing and installing the camshaft housing, pay attention to the seating of the sealing ring between the cylinder head and the camshaft housing (EPC picture no. 80). If this sealing ring is not installed, oil “sweat” may arise around the injector wells.
Although we couldn’t specifically say what has caused this to happen, as can be seen the internal bearing part has failed on the rocker. Multiple had failed. This has caused wear on the camshaft;
As per the Technical Service Bulletin, only the exhaust side has suffered. We opted to replace all rockers and compensating elements (aka tappets, hydraulic elements, buckets) and the camshafts.
Camshaft ssss you say? Well it happens that you can’t buy camshafts on there lonesomes. It can only be purchased as a ‘Camshaft bearing housing’ – A6540502500 (at time of writing, October 2021) £491+ vat. I would say this is due to this unit being the bearing surface for the camshafts, it all wears together, so needs to be replaced together.
Other than a few special locking tools, its a fairly straightforward job. Expect a days work. Official WIS/ASRA time about 7 hours.
Check here for locking tool kit or try this direct link (Please let me know if links broken!)
Due to the setup of the chain and tensioner, the timing chain doesn’t have to be touched. Essentially set to TDC, the cams need to be locked off and remove camshaft bearing carrier complete.
Make sure you replace the seals that you remove whilst getting to it and use new injector seals and bolts.
Camshaft carrier to head gasket – A6540517100
Rocker cover gasket – A6540162200
Rocker cover gasket middle part – A6540160700
Rocker cover gasket small part – A6540164400
New type rocker arm – A6540506601
New type compensating element – A6420500280
Injector copper washer – A6110170060
Injector bolt – A0019902607
Camshafts inc bearing housing – A6540502500
I expect that this will become an issue with the W213 E Class’ getting more mileage on them now, we will see! The date on the TSB is April 2020, hopefully the updated parts were fitted to engines earlier than this.
Edit; Marcin Pakuła: Since 10/07/2018 or from engine number: 80278367 new parts are installed
Get stuck? Need advice? Happy to try and help – contact me on the socials.
