Tag: maintenance

Mercedes CLS55 AMG W219, Replacing The Supercharger Idler Pulley

I noticed that the supercharger idler pulley had quite some dirt accumulation on it and also felt a bit of play, so decided to replace it with a new pulley. I made the right decision as the grease was escaping and therefore attracting the dirt.

Runs smooth again with the new pulley. When I will upgrade with billet pulleys, I will also replace the tensioner itself.

Old (+dirty) and new pulley



Mercedes CLS55 AMG W219, Solving AirMatic Issues

I was suprised with this look, which is a horror type of situation for every CLS owner with Airmatic suspension. In the end I tracked the issue down to a leaking compressor air line (to the valve body), which solved the issue.




Mercedes CLS55 AMG W219, Replacing The Power Steering Reservoir & Fluid

The power steering reservoir on the W211 & W219 platform have a filter built in. This filter is not serviceable, meaning that you need to replace the reservoir if you also want to replace the filter.

I took the liberty to replace the reservoir/filter and also flush the complete system and put fresh new synthetic oil in.

I used a vacuumpump to get most of the old red mineral fluid out. Then replaced the reservoir and used the “lock-to-lock” steering motion to pump all the old fluid out. Temporarily cap off the return line on the new reservoir and extend the return line to any suitable container for the old fluid.

I used about 2 liters to flush the system and 1 liter to fill the system. Febi Bilstein CHF 11-S Nr. 06161 is the correct fluid for this system.

Steering goes noticeably lighter after this service!

Old fluid coming out
Almost done flushing (fluid is becoming more green/blue-ish)
Made this shot after removing the reservoir. It clearly shows why replacing the serpentine belt is a bit of a hassle there…



Mercedes CLS55 AMG W219, Servicing The Supercharger Oil

One of the most common overlooked service items, is replacing the supercharger oil. The gears of the supercharger spin very fast and need proper lubrication and cooling. Because it spins so fast, it requires a special type of oil: Mobil Jet Oil II (Synthetic Jet Engine Oil).

This oil is not that widely available to customers and also not very cheap. I used a 150ml syringe with some hose to extract the oil and fill it up again. It holds 150ml maximum, but you can never get all the oil out unless you remove the supercharger. I removed about 130ml, and put back the same amount in fresh oil.

Extracting the old oil
Used a plastic containter to hold the oil in, which makes it a lot easier



Mercedes CLS55 AMG W219, Replacing The Serpentine Belt

Replaced the serpentine belt, under the guise of “while I am in there”. It was quite a hassle, but unfortunately, I will do it again as this belt seems a little short to my liking. The tensioner has ample room to move this way, which is not how I like to see it.

I replaced it with a Dayco 6PK2440 belt if I am not mistaken.

New and old belt
Dayco belt in place



Mercedes CLS55 AMG W219, Cleaning The Belly Pans

After changing the oil, I was left with 3 dirty belly pans. Actually, the first one was pretty clean. But the 2nd & 3rd were really dirty due to oil leaking and dirt accumulating on that oil.

But a good degreaser and pressure washer work wonders. I totally forgot to take ‘after” pictures, so you will have to believe me on this one 😉

1st belly pan (pretty clean)
2nd belly pan, which was quite dirty. nfortunately, it has 1 broken air diverter
3rd belly pan, this was really dirty!



Mercedes CLS55 AMG W219, My First Oil Change With LiquiMoly 5W40 High Tech

Performed the first oil change on the CLS55 with LiquiMoly High Tech Low Resistance 5W40 oil. Bought 2x 5 Liter canisters, as the big 5.4 Liter takes about 8.5 Liters of oil in total. Also added in 1.5 canister of LiquiMoly Ceratec, a well known working friction modifier.

List:

  • 2x 5 Liter LiquiMoly High Tec Low Resistance 5W40
  • 1x Mann Oil Filter HU718/5X
  • 2x Mercedes Oil Sump Plug A3529970032
  • 1x Katsu Oil Filter Wrench Set

This was my setup for the day, used 2 ramp, which has enough ground clearance.

This is how the oil filter looked. It was in a bad state, seems the previous owner skimped out on maintenance…The rubber O-rings especially were very old and worn.

The M113k engine has 2 sumps, a front scavenging sump and in the back the main sump. I saw a lot of oil leakage, most of it was due to the rocker covers as far as I could judge for now.

Front scavenging sump
Rear main sump
Putting the Katsu oil filter wrench to good use. I used a combination of a vacuumpump with the drain plugs to get most of the old oil out

Performed some other things “while I was in there”, but I will describe that in separate posts.




Mercedes CLS55 AMG W219, Replacing The Rear Differential Oil

1.5 Liter of 75W140 GL5 Differential oil (LiquiMoly) and 2x new filler caps for the rear differential. I didnt have the correct hex key, but a T70 torx also works. Will be doing this again in the near future, so all the old oil is replaced with new oil.

I used a big syringe (150ml), which actually worked out very well. I will always recommend using new plugs whenever you notice that the plugs look old.

Partnr: A3529970032
The old drain plug
The old filler plug on the drivers side

Draining the old rear differential oil

New shiny drain plug
New shiny filler plug



Mercedes CLS55 AMG W219, Replacing The Rocker Cover Gaskets

When I replaced the spark plugs, I noticed some massive oil seepage/leaks from both the rocker covers. I bought the original Mercedes liquid sealant for the breather chambers. I already read that this would be cumbersome, and that was no lie.

But it’s all in the preparation (degrease properly!) and take your time for that, because this is not something you want to do a couple of times.

OE Mercedes sealant partnr: A003989982010

I found out that a deep 18mm socket and 1/2″ extension enabled me to use a kit gun, essentially making the job way easier! If you look closely, you will see the setup in the back of the photo.

Happy to see that all looks well under the rocker covers 🙂




Mercedes CLS55 AMG W219, Replacing K&N Air Filters With OEM Paper Air Filters

Replaced the K&N drop-in filters with OEM paper filters (Febi Bilstein), as I prefer better filtration over a little more throughput. I don’t think I will notice the difference with my standard CLS55 AMG.




Mercedes CLS55 AMG W219, Replacing The Cabin Filter With Mann FreciousPlus Filter

Replaced the cabin filter as I did not know when it was last replaced. I was unaware that Mann had a new type of filter, which transcends the pollen and active carbon filter type.

Their FreciousPlus series is also anti-bacterial, making you stay as healthy as possible within your car 🙂 I used Mann FP3172 for the CLS55. As you can see, it needs to be replaced every year or 15.000km.




Mercedes CLS55 AMG W219, Replacing All 8 Coil Packs

After about 187.000km (or 17 years), the original coil packs are due for retirement in my garage 😉 Car seems to run a little better after placing the new coil packs!

Could also be placebo effect… 😉

Old dusty coil packs with oil leak
8 Brand spanking new coil packs, ready to be installed



Mercedes CLS55 AMG W219, New Vband Clamps For Non-Resonated Catback Exhaust

On of the previous owners clipped something, as the Vband clamps for the non-resonated catback were damaged and therefore leaking (a little bit).

I replaced both of them with brand new clamps, so the seal is airtight again!

Damaged Vband clamps (scraped & dented)



Mercedes CLS55 AMG W219, Changing The 16 Spark Plugs With Beru Ultra Titan UPT14P

Replaced all 16x (!) spark plugs with fresh new Beru UPT14P Ultra Titan Spark plugs. They are pre-gapped at 0.75mm and I adjusted them to 0.8mm as per factory specifications.

They needed to be replaced a little while ago, too bad that some people skimp out on needed maintenance.




Mercedes CLS55 AMG W219, LiquiMoly Injector Cleaner

As part of regular maintenance, bought some LiqiuMoly injection cleaner. Will probably be using this every now and then as preventative maintenance.




Mercedes CLS55 AMG W219, Replacing the Supercharger Pulley Bearing (Nachi)

I decided to replace the supercharger pulley bearing with a fresh new Japan made Nachi bearing. One of the easiest way is the hot/cold method, where you heat up the pulley and freeze the bearing itself. This results in the bearing sliding into the pulley with relative ease.

I could’ve also used my workshop press, but I didn’t want to force it in. I followed this guide for it:

Some more pictures:

All CLS55 AMG pictures here in my Google Photos album: https://photos.app.goo.gl/6SP5PFAUXCqanoSX9




Mini Cooper S R53 JCW – New Downstream O2 Sensor

Replaced the O2 sensor with a fresh new one from Vemo. I totally forgot that the Mini Cooper has 2x O2 sensors 🙂 Don’t forget that O2 sensors have a replacement interval which is usually somewhere between 160.000 – 250.000 km.

Update per 01-01-2021: I replaced the Vemo with a new O2 sensor from Magneti Marelli. The Vemo already started giving issues after a short while. It will be the last time that I will be using Vemo.

Mini Cooper S R53 JCW New Lambda Sensor


Volvo S80 2.4T New Serpentine Belt Tensioner

Finally fitted a new serpentine belt tensioner, needed to wait for a Torx T60 bit to be able to take the tension of when you fit the serpentine belt.

Volvo S80 2.4T New Serpentine Belt Tensioner


Mini Cooper S R53 JCW Heatwrapped Stainless Exhaust

I heatwrapped the new stainless steel Gravity Performance catback exhaust. Unfortunately I ran out of titanium heatwrap, so I ordered some more (black) and finished the job.

It will help with scavenging and is a supporting mod for extracting more horsepower and torque from the Mini.

Mini Cooper S R53 JCW Heatwrapped Stainless Exhaust

Mini Cooper S R53 JCW Heatwrapped Stainless Exhaust


Volvo S80 2.4T Plastidipped Grill

I wanted a cleaner look for the front grill and decided to use plastidip instead of the carbon wrap. It came out great and suits the black S80 very well.

I used Motip Removable Coating instead of classic Plastidip and it holds very well till this day.

Volvo S80 2.4T Plastidipped Grille

Volvo S80 2.4T Plastidipped Grille

Volvo S80 2.4T Plastidipped Grille

Volvo S80 2.4T Plastidipped Grille

Volvo S80 2.4T Plastidipped Grille

Also repainted the front trim with bumperspray (which didn’t hold by the way).

Volvo S80 2.4T Repainted Trim


Volvo S80 2.4T New Engine Mounts

When you have an older car, always think about replacing the engine mounts. They are almost always made of rubber, which becomes brittle over time due to aging/drying out.

I replaced all the engine mounts, which tightens up handling and improves performance and reduces strain on components like the exhaust, as the engine swivels way less. Highly recommended!

Volvo S80 2.4T Engine Mounts

Volvo S80 2.4T Engine Mounts

Volvo S80 2.4T Engine Mounts

Volvo S80 2.4T Engine Mounts


Volvo S80 2.4T Diffuser

Added 2 diffusers to the rear bumper of the S80. Looks very nice and makes the S80 less of a Old Man car haha 🙂

URL: https://www.aliexpress.com/item/32853258621.html

Volvo S80 2.4T Diffuser

Volvo S80 2.4T Diffuser


Volvo S80 2.4T Replacing the Car Battery

Replaced the old battery with a fresh new battery. Decided to mount a larger type, as the S80 has room for it.

See the big difference in size, which should account for a little bit more performance and safety as it has a lot more power.

Link to product: https://www.ebay.com/itm/252638760566

Chose a Powerline with the following specifications:

Spanning12 Volts
Capaciteit (C20)82 Ah
Capaciteit (C100)90 Ah
Koude start Amps (EN)680 A
Koude start Amps (SAE)730 A
Lengte353 mm
Breedte175 mm
Hoogte190 mm

Volvo S80 2.4T Replacing the Car Battery

Volvo S80 2.4T Replacing the Car Battery

Volvo S80 2.4T Replacing the Car Battery

Volvo S80 2.4T Replacing the Car Battery


Volvo S80 2.4T PCV DIY Repair / Service

Repaired / cleaned the PCV circuit as I saw a lot of oil in the pressure circuit (also see my previous post: https://www.ducked.nl/blog-entries/volvo-s80-2-4t-dirty-clean-turbo-coldside/ ).

Did a little research and the PCV system is almost always the culprit for such issues.

Decided to buy a complete system although ended up cleaning the existing system and only replacing the oil seperator. The tubing was quite some work, I will save that for another time.

Volvo S80 2.4T PCV Repair

Volvo S80 2.4T PCV Repair

Volvo S80 2.4T Clean Valves :)

Volvo S80 2.4T PCV Repair

Volvo S80 2.4T PCV Repair


Volvo S80 2.4T Dirty / Clean Turbo Coldside

Replaced the air filter and the turbo intake pipe. Please note that a dirty intake might also point out a badly functioning PCV system!

The intake pipe was upgraded to a blue Do88.se / Do88 silicone intake pipe, which is a fair bit larger, but also deletes some bottlenecks from the original part (like the narrowing bend on the bottom and the “harmonica”).

Gives a little bit more power from the butt dyno and noticed more intake growl (which is a good thing) 🙂

Volvo S80 2.4T Dirty Turbo Coldside

Volvo S80 2.4T Cleaned Turbo Coldside


Volvo S80 2.4T DO88.se Turbo Intake pipe

Replaced the air filter and the turbo intake pipe.

The intake pipe was upgraded to a blue Do88.se / Do88 silicone intake pipe, which is a fair bit larger, but also deletes some bottlenecks from the original part (like the narrowing bend on the bottom and the “harmonica”).

Gives a little bit more power from the butt dyno and noticed more intake growl (which is a good thing) 🙂

Volvo S80 2.4T Do88 Turbo Intake pipe

Volvo S80 2.4T OEM vs Do88 Turbo Intake Pipe

Volvo S80 2.4T OEM vs Do88 Turbo Intake Pipe

Volvo S80 2.4T OEM vs Do88 Turbo Intake Pipe

Volvo S80 2.4T Modified PTC Sensor


Volvo S80 2.4T Dirty vs New Airfilter

Replaced the air filter. This is what a dirty airfilter looks like.

Change it on time, so your car keeps performing at peak efficiency!

Volvo S80 2.4T Dirty vs New Airfilter


Volvo S80 2.4T Painting the Brake Calipers Daytona Yellow

Decided to paint the calipers for extra flair and to be honest it looks way better than that rusty brown color.

Bought some MHW Daytona Yellow paint and combined it with the yellow Prancing moose shield.

Volvo S80 2.4T Painting the Brake Calipers Daytona Yellow

Volvo S80 2.4T Painting the Brake Calipers Daytona Yellow

Volvo S80 2.4T Painting the Brake Calipers Daytona Yellow

Volvo S80 2.4T New Volvo Hubcap Stickers


Volvo S80 2.4T Changing the Interior Combo filter

Needed to change the interior / combofilter and was suprised by this malformed unit.

Looks like someone didnt do their job properly…Shameful really.

Easy DIY job, which shouldn’t take more than half an hour.

Volvo S80 2.4T Changing the Combo filter


Volvo S80 2.4T Soundproofing

When I last performed maintenance to the window sliders, I noticed the doors had not been soundproofed yet. Bought me a big mat on Aliexpress and went to work today.

Door card removal is very easy on the Volvo, so I was done in a very small time frame, which is always nice. The impact of such a simple thing like soundproofing is always noticeable, as the resonance from the tinny doors are removed, which allows for better sounding music + less cabin sound/drone.

Highly recommended & easy to do yourself!

Volvo S80 2.4T Soundproofing

Volvo S80 2.4T Soundproofing


Volvo S80 2.4T Denso Injector Service

Decided to clean and service the stock Denso injectors. Rubber rings get hard and brittle over time and tend to leak. Also the filter baskets might be contaminated over time, especially if the fuel filter is not part of your regular service intervals (which mine S80 lacked…).

I bought this kit of Aliexpress and the quality looks very nice. It contains all the items needed, including a special tool for removing/mounting the filter baskets.

The pictures will speak for themselves (it was needed!).

Volvo S80 2.4T Denso Injector Service
Volvo S80 2.4T Denso Injector Service
Volvo S80 2.4T Denso Injector Service
Volvo S80 2.4T Denso Injector Service

A very old fuel filter.

Volvo S80 2.4T Old Fuel filter





Volvo S80 2.4T Changing Spark Plugs (NGK K20TT 4604)

Fitted some fresh new plugs and decided to try NGK copper plug instead of Volvo OEM Iridium plugs. They work great and cost next to nothing. Decided to try NGK K20TT 4606. Double checked the gap to be sure, they are correctly preset for the Volvo S80 2.4 / 2.5T.

Still have to get used to swapping out 5 spark plugs instead of the “usual” 4.

Volvo S80 2.4T Changing Spark plugs

Volvo S80 2.4T Changing Spark plugs

Volvo S80 2.4T Changing Spark plugs




Volvo S80 2.4T Fitting a new Compressor Bypass Valve (CBV)

I noticed some strange behaviour when lifting the throttle and decided to service the CBV aka Compressor Bypass Valve. I was right, car drives a lot better after replacing it with a fresh CBV / DV (Diverter Valve).

I went with an aftermarket TRITDT K5T09671.

Volvo S80 2.4T New TRITDT Compressor Bypass Valve (CBV) repair kit

Volvo S80 2.4T New TRITDT Compressor Bypass Valve (CBV) vs Old

Volvo S80 2.4T New TRITDT Compressor Bypass Valve (CBV) vs Old

Volvo S80 2.4T Fitting a new Compressor Bypass Valve (CBV)




Volvo S80 2.4T Replacing Window Sliders

Easy mod with big results. If you have a Volvo with a choppy window, 9 out of 10, it will be the window sliders. They are quite easy to replace though. Tip: buy them on Aliexpress for cheap!

Volvo S80 2.4T Repairing Window Mechanism

Volvo S80 2.4T Repairing Window Mechanism

Volvo S80 2.4T Repairing Window Mechanism




Volvo S80 2.4T Replacing the Bosch O2 Lambda Sensor

Many people tend to forget that O2 aka Lambda sensors have a replacement interval (in my case 250.000km). Failing to do so will have direct impact on your power and mileage. I checked using Torque (Android app) and checking the Long Term Fuel Trims (LTFT). I noticed that they dropped after installing the new Bosch O2 sensor.

Partnr: 0 258 007 137 / 0258007137
LSU42, LS7137
EAN: 3165143196243

Volvo S80 2.4T Bosch O2 Precat Lambda Sensor

Volvo S80 2.4T Bosch O2 Precat Lambda Sensor

Volvo S80 2.4T Bosch O2 Precat Lambda Sensor




Volvo S80 2.4T LED License Plate Lights

Upgraded / updated the License plate lights to LED versions, which look much better than the stock items. Highly recommended mod!

Volvo S80 2.4T LED License Plate Lights

Volvo S80 2.4T LED License Plate Lights




Volvo S80 2.4T Repainting All The Trim

When I bought the S80, it was evident that the plastic trim had seen better days. So I decided to spend some time and repaint it black. As expected, it transformed the car tremendously. I highly recommend this!

Volvo S80 2.4T Repainting All The Trim!

Volvo S80 2.4T Repainting All The Trim!

Volvo S80 2.4T Repainting All The Trim!

Volvo S80 2.4T Repainting All The Trim!

Volvo S80 2.4T Repainting All The Trim!

Volvo S80 2.4T Repainting All The Trim!

Volvo S80 2.4T Repainting All The Trim!

Volvo S80 2.4T Repainting All The Trim!




Volvo S80 2.4T Replacing vacuum lines with Silicone Hoses

A highly recommended repair / modification for all older Volvo owners. Replacing the old rubber vacuum lines with strong durable silicone hoses. I bought 3 color hoses (red / black/ blue) as the original hoses also have color stamps on them. Old rubber hoses deteriorate from heat and moisture and will fail over time. Replacing them with silicone hoses ensures a proper running car!

Volvo S80 2.4T Replacing Vacuum Lines




Volvo S80 2.4T Upgrading Interior Lights with LEDs

To modernize the car and make it more future proof, I decided the replace as much halogen bulbs with LEDs. I didn’t want the 6500k Blueish tint, but instead opted for a warmer white color, which are a little bit more white than their halogen counterparts. Very happy with the end result!

Old

Volvo S80 2.4T Rear Vanity Lights LED

And New

Volvo S80 2.4T Rear Vanity Lights Halogen

Upgrading the rear light dome cluster

Volvo S80 2.4T Rear Light Cluster

Halogen vs LED

Volvo S80 2.4T Rear Light Cluster Halogen vs LED

Volvo S80 2.4T Rear Light Cluster Halogen vs LED

Warm white Festoon LEDs

Volvo S80 2.4T Rear Light Cluster

Unhooking the tab

Volvo S80 2.4T Rear Light Cluster

End result for the rear light cluster

Volvo S80 2.4T Rear light cluster after LED replacements

Front cluster

Volvo S80 2.4T Front Light Cluster

Volvo S80 2.4T Front Light Cluster




Volvo S80 2.4T Replacing the Upper Engine Mount with SuperPro Polybush

I noticed that when lifting off (like shifting), there was a lot of movement / play in the engine / gearbox. So when I inspected the upper engine mount, I found the root cause rather quickly. The rubber deteriorated and there wasn’t much left of the original rubber bushing.

Having read the other options, like fitting a polybush, I went with the SuperPro version which looked like a good bit of kit. Mounting the new polyurethane kit was quite a breeze. Fortunately, the original bushing has a plastic ring 🙂 The SuperPro kit consists of 2 pieces, which makes the mount very easy to replace.

Result: a much better shifting car, putting the power down goes a lot better now. I will also replace the bottom gearbox mount with a polyurethane version soon.

Very easy job to do at home. This also applies to the S60 and V70, as these are quite identical.

Broken upper engine mount…

Volvo S80 2.4T worn engine mount

Tearing it down

Volvo S80 2.4T Removing the Upper Engine Mount OEM bushing

Volvo S80 2.4T Upper Engine Mount shot OEM bush

Comparing old to new

Volvo S80 2.4T Polyurethane Upper Engine Mount vs OEM top view

Volvo S80 2.4T Polyurethane Upper Engine Mount vs OEM side view

Et voila!

Volvo S80 2.4T Polyurethane Upper Engine Mount completed




Vw Golf MK3 GTI, Repaint All The Trim

As the car is quite old, the plastic trim of the car has been exposed to the influence of the sun for countless of times, which greys out the once black plastic trim. I decided to repaint it all, as the grey trim is just plain ugly. The most work was to mask of the rest of the car, the rest was easy 🙂

Work in progress
VW Golf MK3 GTI / Painting the trim matte black again

Ugly greyed out trim…

VW Golf MK3 / Old Grey Trim

VW Golf MK3 / Old Grey Trim




VW Golf MK3 GTI, New Fuel Pump

As the car is about 21 years old, it was about time the fuel pump was renewed. A fuel pump gets old and will be unable to deliver the desired fuel pressure when needed. This will have a big impact on the performance as you might imagine. It took me quite some time as the retaining ring was stuck, like real stuck…

I was finally able to prise it of, but needed to perform some cleaning before putting in the new pump. But it was worth it!

Partnr: 1H0919051AK

Dirty pump
VW Golf MK3 GTI / Replacing the Fuel Pump 1H0919051AK

Fresh new pump!

VW Golf MK3 GTI / Replacing the Fuel Pump 1H0919051AK




VW Golf MK3 GTI, Maintenance time

Performed some big maintenance work on the Golf GTI as this was highly needed. Always feels good when it has been done, in a nutshell:

  • Oil change (5W40)
  • Brake fluid change (DOT 4)
  • Fuel filter change
  • Oil filter change
  • New PCV / Oil Seperator valve
  • New Ignition coil
  • New Coolant Temperature sensor
  • New Air filter element
  • New interior filter (active carbon filter)
  • New Bosch Aerotwin Wiper blades
  • New Brake pads front + back

Maintenance time




Swapping out the VW Golf MK3 GTI Crankshaft Position Sensor

My car was cutting out when the engine was hot. RPM gauge dropped to zero instantly & engine cuts out immediateley. Scanning the car with vagcom / VCDS showed an error with the G28 sensor aka Crankshaft Position sensor. Other names are Engine Speed sensor and in Dutch BDP sensor or krukaspositie sensor.

I followed this video guide, which helped me tremendously, so thank you Thomas EXOVCDS. Took me about an hour on axle stands, so not that bad.




VW Lupo 1.4 old sparkplugs replaced

Driving 140km a couple times per week stresses the car more than you would think. Keeping it in tip top shape is important, even more so with an older car like our VW Lupo which was born in 1999 (1.4 16v, engine code AHW). Less than a year when the last service was done, I checked the spark plugs (as it was starting a bit rough). Look at the picture to understand why…

Please note that I needed to wait before the NGK Iridium sparkplugs (type: BKR6EIX-11 3764) were delivered, So I bent the old one, so that the gap was made smaller.

 VW Lupo New NGK Iridum vs Old




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groeten Andy