Mercedes Vito Van 2009 OM646 111 2.1 CDI 'Diesel Black Death' Injector Seal Replacement How To

We recently purchased a Mercedes Vito 2009 (111, OM646) 2.1 CDI Diesel van, it had trouble starting when warm and also you could smell exhaust fumes when driving so decided to investigate and found that we had more than one 'chuffing injector' or leaky injector seal causing the problems, smell and a huge build up of carbon around the injectors/wiring/pipes that had to be chipped off carefully and then vacuumed (don't use sprays, chip at it) so we could get access to remove the injectors and replace the failed copper washer seals. This is sometimes known as 'Black Death' due to 'Chuffing Injectors'.

We made this video showing the process from start to finish, hopefully it's helpful if you have the same problem and we've tried to include as much information as possible but if you have any questions let us know thanks. This information also applies to the sprinter vans too.

You will need quite a few tools, time and patience and we did replace the leak off pipe along with injector electrical plug connector as they were toast brittle and broken. The tools you'll need are: a torque wrench with degrees for (7Nm + x 2 90 degrees turns for injector bolts), injector reseating tool and a slide hammer to remove injectors plug other misc items.

Bolts and seals pack (x4):
https://amzn.to/3GcdoLW

Electrical connector plugs (prewired x4):
https://amzn.to/3uuNiRW

Leak off pipe:
https://www.ebay.co.uk/itm/363524024573

Injector puller slide hammer kit:
https://amzn.to/3QPdLkz

Injector Reseating Tool:
https://amzn.to/40Ri8Af

#mercedesvito #mercedessprinter #om646