Mercedes W203 cdi injector seal repair - How to repair leaking injector DIY - black death 

Original instructions from Mercedes:7 Nm and 1x 90 degrees. Later instructions: 7 Nm an 2 times 90 degrees.

ANy updates on how that went? Do you feel the tools were necessary/helpful? I have a 2005 CDI with the same issue.

bump

Where did you order from ?

Hello, you need an M6 tap, something like this: www.aliexpress.com/w/wholesale-M6-thread-cutting-tool.html?spm=2114.search0104.0.0.ijAuau&initiative_id=SB_20171209024038&site=glo&groupsort=1&SortType=price_asc&g=y&SearchText=M6+thread+cutting+tool With this you can make sure the thread is clean all up to the bottom of the hole, so that the bolt can be thightened enough. As you know: if the thread is not cleaned untill the bottom, then the new bolt willl probably hit onto the dirt in the bottom of the threaded hole: you would think you tightened it: but it will be hitting on the dirt on the bottom of the hole.

LaurensW203 Ok, thanks. Also, do you know what the thread pitch is? 1mm, .75mm, or .5mm?

it is M6x1 which is the standard M6 size.

Thanks again! I was fairly certain, but not 100%. I haven't started the job yet, but I'm getting the tools needed : )

Did you depressurize the fuel line before doing yours?

well fitted new injector and did as above and it fired straight up

These injectors get very hard to pull out after time and normal oil or grease will harden over time, so I think your injectors might be baked solid and will be impossible to remove any next time. Therefore I used Molycote high temperature grease. Perhaps you could use some cupper-grease because such cupper-grease is also used for high temperature use. Just ask / buy in you local car-repair-shop. Succes!

Hello Endrit, yes I did have the diesel-smell inside the car. But I did not notice any starting problems. You should just check if there is black sludge around the injectors: it is easy to see as the only thing you need to do is to pull of the black engine cover and you can see the injectors. Just check if you see the black sludge. With the cover removed you might also hear the sissing noise of the leaking combustion gasses that escape from the leaking injector seal. Good luck!

LaurensW203 Hello Laurens. I am going right now at the mechanic. Just to know, how long did you let this issue not fixed? I have to make a trip of around 500 km and want to know whats the worst thing that might happen.

LaurensW203 Problem fixed. The main hose that brings fuel to the fuel filter was damaged and a little loose from wear/time. I cut the tip and refitted. Now its fine. But I guess I will replace the hose with a new one.

well done!

You can buy from eBay: look for metric tap thread. Chinese quality Will do the job as in this case is for recutting the thread inkt. Succes!

You need to get star diagnosis. Buy one from AliExpress. ~400$.