I am getting ready to do this repair on my 2006 E320 CDI. I have a read up a bit on it and know"

1. Get the engine warm so it turns from hard to goo
2. Clean everything well
3. Clean thready on injector hold down bolt hole as if any goo is in the bottom it can break through the valve cover
4. Replace the bolts as they are one-time use stretch bolts
5. Do not use the thread on injector puller with a slide hammer as it will most likely damage the injector
6. Make sure to use the tool to clean the deposits and etching from where the injector/crush washer sit on the head as well as on the injector.


I have heard that the Honda 2.2L Diesel copper crush washer is a similar size, but a bit thicker and softer and may seal better. Is this true? Is there a better crush washer that is currently used? What is the part number on the Honda one?


Anyone else have any other pointers or tips on this service?

No personal knowledge

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1999 Mercedes E300TD daily driver sold at 238K miles 106K miles were mine, rust worm got it :-(
2006 Mercedes CDI new daily driver! 56,000 miles May 2016 now 85,625 Apr 2018 and Apr 2019 101,000 miles Apr 2020 109,875. March 2024 135,250

Some info here with some excellent links to it and mention of the Honda injector washer
Mercedes Diesel Injector Advice

all of what you said. Getting the engine hot when you need to pull the injector is the biggie. If i could redo it, i would get it warm and clean the area good. Then get it good and hot and pull the injectors. i used the mercedes seals, but have been told Honda makes a better one. The parts for 6 injectors were like 13 bucks, seals and bolts.
Buy the long torx sockets 4-6 inch long. You will be glad you did.
When you tighten the bolts, clean the heck out of the holes, then blow them out really good with an air blower. then when you tighten them, its 7 NM plus a quarter turn, no more...
Good luck, not a hard job on a hot engine, on a 211, in a sprinter or ML, access may be an issue.

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1959 Gravely LI, 1963 Gravely L8, 1973 Gravely C12
1982 380SL
1978 450 SEL 6.9 euro restoration at 63% and climbing
1987 300 D
2005 CDI European Delivery
2006 CDI Handed down to daughter
2007 GL CDI. Wifes

Here is the FSM info for the TTY bolts.


TQ specs on the hold down bolt: 7Nm + 90d+ 90d.

Good info here. http://www.benzworld.org/forums/w211-e-class/2238946-e320-cdi-black-death.html

John

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Certified Registered Nurse Anesthetist (CRNA)
2002 F250 powerstroke with Plantdrive WVO conversion
1983 300SD 190K miles ,sold
2006 E320 CDI

This Beru pdf has some great info http://www.beru.com/download/produkte/TI04_en.pdf

Search for shear torque

Glow plug Shear
thread torque
8 mm 20 Nm
9 mm 22 Nm
10 mm 35 Nm
12 mm 45 Nm

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85 300D turbo pristine w 157k when purchased 161K now
83 300 D turbo 297K runs great. SOLD!
83 240D 4 spd manual- parted out then junked

Thanks for all the replies on fixing the black death, I've got some reading to do!


Also, good info on the glow plugs. I have a code for a glow plug and was also going to replace it.


Updated chart to show ft/lb and in/lb:


Glow plug Shear

Thread Torque
8 mm 20 Nm 15 ft/lb 177 in/lb
9 mm 22 Nm 16 ft/lb 195 in/lb
10 mm 35 Nm 26 ft/lb 310 in/lb
12 mm 45 Nm 33 ft/lb 398 in/lb



Glow plug Torque Spec

Thread Torque
8 mm 10 Nm
9 mm 12 Nm
10 mm 12-18 Nm
12 mm 22-25 Nm