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OWNER MikeinTampa

The full code list is available in the PDF attached to the first post in this thread.

Anyway - code 4 is for the air/smog pump. If the pump is running at a cold start, check all the vacuum tubing from the engine, to the solenoid on the fender, and back to the air valve at the pump. None of this affects engine function or power, it's primarily affecting emissions after a cold start. The O2 sensor is probably fine, but if it's old a new one is always a good idea.

Does the smog pump turn on and off like an A/C compressor? I noticed a noise which sounds like a noisy ac compressor when engaged. I was just looking at the smog pump bearing thread. Don't think its the pump because its not constant. I will check all the vacuum lines however. Is there a diagram that shows where all the vacuum lines are?
 
Does the smog pump turn on and off like an A/C compressor? I noticed a noise which sounds like a noisy ac compressor when engaged. I was just looking at the smog pump bearing thread. Don't think its the pump because its not constant. I will check all the vacuum lines however. Is there a diagram that shows where all the vacuum lines are?
Yes, it has an electric clutch that turns it on/off just like the AC compressor. Normally it runs for a couple minutes after a cold start to heat the catalysts faster, but it can engage randomly on a warm engine to reduce emissions as well. If the pump is starting to go bad, they can get rather noisy. Good ones are very quiet. Most of the time the engine is running, the pump does not run.

There should be a silver decal above the driver headlight with a vacuum diagram. There is a test which can be done in the SDS/HHT-Win to confirm pump operation, but if the issue is intermittent, it may pass the test. If so, it can be difficult to pinpoint the root cause.

:detective:
 
Cam Seal Update

I pulled off the distributor cap, rotor, and bracket to check the seal after driving the car a few times this week. So far it's holding up and I don't see any signs of leaks. For how long? TBD..
 

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Spark plugs

I decided to finally swap out the spark plugs today. Well, I found what was probably causing most of my slightly rough idle issue.. also, 2 of the spark plugs were so loose I unscrewed them by hand.. :omg:

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Ohhh man... good mechanic was working before!
Time for news cabels too..
 
Dont you just want to walk up to the clown and bitch slap them for that lack of professionalism?
 
Make sure to clean all the oil out of the spark plug wells... this can be a real nuisance. Also, make certain the valve cover gaskets are not leaking oil into the well or you could end up with an oily mess again. Might need to check a few hundred miles after cleaning it up to confirm they're all dry.

:v8:
 
Make sure to clean all the oil out of the spark plug wells... this can be a real nuisance. Also, make certain the valve cover gaskets are not leaking oil into the well or you could end up with an oily mess again. Might need to check a few hundred miles after cleaning it up to confirm they're all dry.

I came up with a fairly easy way to clean up the wells with what I had available. I took a large flathead screwdriver and I wrapped half a sheet of paper towel around the screwdriver tightly and folded over the tip, gently put it in the well and twisted it a few times, changed the paper towel and did it again for each well. It worked quite well. For the cables, I did the same thing with a really small screwdriver and a small piece of paper towel a few times for each cable. I'll probably need to change the cables anyway since there was so much oil on 5 out of the 8 cables. Those valve cover gaskets must be pretty bad.
 
I came up with a fairly easy way to clean up the wells with what I had available. I took a large flathead screwdriver and I wrapped half a sheet of paper towel around the screwdriver tightly and folded over the tip, gently put it in the well and twisted it a few times, changed the paper towel and did it again for each well. It worked quite well.
That's the same method I use! For the final wipe I'll spray the paper towel with carb/brake cleaner.

The oil may or may not be coming from the valve cover gasket/seal, it COULD have come up past the spark plug threads on the loose plugs. If you don't see any evidence of oil leaking from the seal at the top by the v/c, it may be coming past the threads.

:klink:
 
I'll spray the paper towel with carb/brake cleaner.
You use brake cleaner? What's this world coming to?

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I bet its the whimpy non-chlorinated type
Nope. Gerry converted me to the good red-can stuff that's illegal in CA. Available here if you don't have a local vendor that carries it (and no, they won't ship to CA).

:nos:
 
That's the same method I use! For the final wipe I'll spray the paper towel with carb/brake cleaner.

The oil may or may not be coming from the valve cover gasket/seal, it COULD have come up past the spark plug threads on the loose plugs. If you don't see any evidence of oil leaking from the seal at the top by the v/c, it may be coming past the threads.

:klink:

I realized I was out of brake cleaner AFTER I already had everything apart and pulled the first plug. I wasn't expecting all the oil. :doh:
 
I purchased a set of Beru W0133-1599712 ignition cables. I bought them from partsgeek.com for $196. The reviews said they are genuine, excellent quality and the lengths are perfect for the m119 engine. Any experts care to chime in on these? Will they be numbered? I'm hoping installation wont be too confusing. What is the best method for installing spark plug wires on the 500E?

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Take one out, find the correct new one and back in! they are not numbered!

(Maybe Cross Check again, Caps are marked with R1, L1 etc. (R,L stands for the Side where the Cap is mounted) and cylinder order. Passenger Side Front is 1, Rear 4 & Driver Side Front is 5, Rear 8.)
 
Mike,
Did you happen to have a little smoke coming out of the tailpipe at start up?
I am wondering if oil that migrate due to bad valve cover seals causes smoke at start up?
I realized I was out of brake cleaner AFTER I already had everything apart and pulled the first plug. I wasn't expecting all the oil. :doh:
 
Take one out, find the correct new one and back in! they are not numbered!

(Maybe Cross Check again, Caps are marked with R1, L1 etc. (R,L stands for the Side where the Cap is mounted) and cylinder order. Passenger Side Front is 1, Rear 4 & Driver Side Front is 5, Rear 8.)

I would do it that way but the problem is that right now a few of the old cables are too long. Judging by condition of the ignition system, who knows who had their hands on it before and if the right length wires are going to the right cylinders in the first place? It would be nice if I had some sort of diagram or list showing how long each cylinder wire should be. That way it would be easiest to number the proper length wires ahead of time and then install them all at once, especially for someone with OCD such as myself. :hehehe:
 
Mike,
Did you happen to have a little smoke coming out of the tailpipe at start up?
I am wondering if oil that migrate due to bad valve cover seals causes smoke at start up?

I have not noticed any smoke but I will look closer next time I start it up. I don't think it smoked at all before, especially now after I cleaned out the oil.

Even thought the rotor brackets have a positioning slot, they have a tiny play in them.
Does that little play affect any thing.

I did notice that slight play I don't think it affects anything.. but I'm no pro on these engines either.
 
The following measurements apply to Beru wires. Measurements are from rubber nipple to nipple or just the wire cable itself. The caps are labeled for left or right application so install the correct length wire at a terminal that has at least one of the letter/number Designations working on one cap at a time. Use bb1s' information below to keep firing order correct or install one wire at a time.

Passenger or right side cap

R1= 840mm

R4 = 955mm

R7 = 890mm

R6 = 930mm

Coil = 505mm

Drivers or left side cap

L2 = 870mm

L3 = 935mm

L5 = 785mm

L8 = 740mm

Coil = 125mm

Drew
 
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The following measurements apply to Beru wires. Measurements are from rubber nipple to nipple or just the wire cable itself. The caps are labeled for left or right application so install the correct length wire at a terminal that has at least one of the letter/number Designations working on one cap at a time. Use bb1s' information below to keep firing order correct or install one wire at a time. ...

This will be very helpful. Thank you!
 
Passenger or right side cap ... (snip) Drew

I used the chart in post #64 in this thread:
http://www.500eboard.com/forums/showthread.php?t=1313&highlight=spark+cable+length

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I laid out the cables from shortest to longest then I numbered them accordingly. The old wires were a mess and some were not even routed correctly thru the x-tray so the one-by-one replacement method was out the window. I removed the driver's side headlight, power steering reservoir bracket, and a few other plugs and vacuum lines and yanked out all the old ignition wires and started with a fresh install. I got a bit nervous once I got to the point of no return with all the cables removed but after carefully studying the numbers on the x-tray I slowly began installing the cables one by one and installation ended up being fairly easy and was a success. I'm very happy with the end result, everything looks very clean and all the wires were perfect length.

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Looks great. Where did you buy the Beru wires from? Did the wires have Beru plug boots as well?

:deniro:
 
Dave, see post #117. They came in a sealed Beru bag and everything looked original. I'm assuming they would have Beru boots right?
Wooops, I missed #117 when scrolling back up the thread. :doh:

If the package was Beru branded, yes, the boots should also be Beru. I've seen mixed brands on a set of wires but generally under a different name, i.e. Karlyn/STI or something... generally with Bremi or unbranded boots at one or both ends.

:jono:
 
I'm still having the low idle issue with my car. Last Sunday we took my car out to run some errands and after driving the car for a couple of hours in the warm weather I noticed the warmer it got the lower the oil pressure would drop at idle. When its at max operating temp during a hot day the rpms are around 500 and oil pressure drops to nearly 0 when at a stop light in gear. There's a slight shake as well. If I could get the rpms up 50-100 at idle I think it would be perfect. So far I have run 2 full tanks with techron additive, changed air filters, cleaned the throttle body walls with carb cleaner, changed distributor caps and rotors, installed new spark plugs and all new ignition cables, and inspected the vacuum lines on the engine. Is there anything else that may affect the idle on these cars?
 
Normal idle speed when fully warmed up is 500rpm in gear, and ~650 in P or N. Unfortunately the idle speed is not adjustable.

The oil pressure near zero is most likely due to an old pressure sender at the base of the oil filter housing, a new VDO/Hella sending unit may help. If there's no record of replacement, there is a date code on the sender but it may be hard to read with it on the car. If the sender is recent, the gauge may be reading low, OR your oil viscosity is low. What brand/viscosity oil are you running? In general it should read 1.0 bar or higher at hot idle, although official min spec is 0.5 bar, IIRC.

The other main item that affects idle is engine mounts... if they are not recent, they are highly suspect. Again, if there are no records you can check the date code on the mounts, and/or measure to see if they have collapsed (photo attached). Only use OE or OEM Boge mounts; last I heard Lemforder was still selling reboxed Boge. OE is crazy priced.

:124fast:
 

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Normal idle speed when fully warmed up is 500rpm in gear, and ~650 in P or N. Unfortunately the idle speed is not adjustable.

The oil pressure near zero is most likely due to an old pressure sender at the base of the oil filter housing, a new VDO/Hella sending unit may help. If there's no record of replacement, there is a date code on the sender but it may be hard to read with it on the car. If the sender is recent, the gauge may be reading low, OR your oil viscosity is low. What brand/viscosity oil are you running? In general it should read 1.0 bar or higher at hot idle, although official min spec is 0.5 bar, IIRC.

The other main item that affects idle is engine mounts... if they are not recent, they are highly suspect. Again, if there are no records you can check the date code on the mounts, and/or measure to see if they have collapsed (photo attached). Only use OE or OEM Boge mounts; last I heard Lemforder was still selling reboxed Boge. OE is crazy priced.

I remember you mentioning the mounts before, I have not looked into them yet. As for the oil, I'm currently running Redline 10w40.
 
I remember you mentioning the mounts before, I have not looked into them yet. As for the oil, I'm currently running Redline 10w40.
Redline 10w40 is good stuff, I run that in all my M119's. If the pressure sender is old / original, that may cure the low pressure reading at idle.

:roadrunner:
 
Happy 2020 to all! Haven’t posted in quite a while. I’ve made a few changes to the car since. I removed the wiper delete headlight fillers and installed a complete OEM headlight wiper set. To finish it off nicely, I also installed original euro amber hella turn signals and removed the yellow protective fog light film. I sold the 18” BBS wheels as well and put the car back to 100% stock with the 16“ stock wheels. I added hub centric H&R 20mm spacers and extended lug bolts to give it a nice slightly wider stance. The car rides, feels, and looks better than ever. IMO

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Happy 2020 to all! Haven’t posted in quite a while. I’ve made a few changes to the car since. I removed the wiper delete headlight fillers and installed a complete OEM headlight wiper set. To finish it off nicely, I also installed original euro amber hella turn signals and removed the yellow protective fog light film. I sold the 18” BBS wheels as well and put the car back to 100% stock with the 16“ stock wheels. I added hub centric H&R 20mm spacers and extended lug bolts to give it a nice slightly wider stance. The car rides, feels, and looks better than ever. IMO

View attachment 92022
View attachment 92023
View attachment 92024
Would be great to see some more photos of the car's new stance with the stock wheels, Mike
 
Hey guys, hope you all have been doing well! I figure I’d post another update. It’s been another 4 years or so since my last post but not too much has changed. The car is doing very well and looking better than ever, except for a slight issue that has recently come up which I will get to in a minute.

So, I have made a couple of changes to the appearance in the past couple of years. Due to limited tire options for 16” wheels, I decided to get a new set of 17” evo wheels wrapped in Michelin Primacy MXM4 245/45/17 for a perfect stance. Also, I ended up doing an entire custom cat back exhaust system due to a catalytic converter failure. I got new cats, a stainless mid muffler and a direct fit AMG rear muffler and tips imported from Europe.

Mechanically, the car needed new fuel pumps so it got a new set of Bosch pimps and a fuel filter. Next, I updated the entire ignition system (again!) due to a misfire that came back. New Bosch F8DC4 plugs, Beru cables, and oem Bosch caps and rotors did the trick and got that smooth idle back.

The AC got warm due to a small leak which got bigger over time. The system wouldn’t hold a charge for more than a couple of weeks so I took the car in and got that addressed. Ended up needing to rebuild the compressor hoses and did an entire AC system tuneup. Air is still ice cold after about a year so that issue has been resolved. I rebuilt the low speed fan regulator as well due to a burned out connector so everything works perfectly now as far as the ac is concerned.

Since updating these few things and getting the car to perfect running condition, I’ve decided to list the car for sale! I listed the car on FB Marketplace and 2 days later, she let me know how unhappy she was about that!

This brings me to that slight issue I mentioned earlier. I go to get in the car and move it so I can wash my 911 and BAM!! You’re not going anywhere buddy.. The steering lock mechanism decided to lock up and not allow me to turn the ignition lock except for maybe 1/4” turn. Not enough to engage any pins to take anything apart. SMH.. frustrating to say the least. With no parts to be found for this, I’ve been trying to figure out how the heck I’m going to get this issue resolved without doing any damage. Funny enough, I am an automotive locksmith of 25 years and yes I’ve done all the steps possible to try to get this thing to turn but no luck.

Anyway, here are some updated photos of the car I took just 2 days before all this happened. Meanwhile I’ll just scratch my head and see what other ideas come to mind so I can get this steering lock out..
 

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Mechanically, the car needed new fuel pumps so it got a new set of Bosch pimps and a fuel filter. Next, I updated the entire ignition system (again!) due to a misfire that came back. New Bosch F8DC4 plugs, Beru cables, and oem Bosch caps and rotors did the trick and got that smooth idle back.
Cutting additional vent slots in the new caps (details here) should help keep the misfire from returning... but, also must eliminate oil leaks from the intake cam solenoids as well.


Since updating these few things and getting the car to perfect running condition, I’ve decided to list the car for sale! I listed the car on FB Marketplace and 2 days later, she let me know how unhappy she was about that!
Noooo! Sorry to hear that. Make sure to list the car in the classified section here, you're more likely to get serious buyers than the usual Facebook muppets.



This brings me to that slight issue I mentioned earlier. I go to get in the car and move it so I can wash my 911 and BAM!! You’re not going anywhere buddy.. The steering lock mechanism decided to lock up and not allow me to turn the ignition lock except for maybe 1/4” turn. Not enough to engage any pins to take anything apart. SMH.. frustrating to say the least. With no parts to be found for this, I’ve been trying to figure out how the heck I’m going to get this issue resolved without doing any damage. Funny enough, I am an automotive locksmith of 25 years and yes I’ve done all the steps possible to try to get this thing to turn but no luck.

Anyway, here are some updated photos of the car I took just 2 days before all this happened. Meanwhile I’ll just scratch my head and see what other ideas come to mind so I can get this steering lock out..
Oh nuts. Is the problem the ignition lock tumbler, or the lock mechanism that the tumbler goes into? The tumbler is still available new, VIN coded, from the dealer. But the lock mechanism assembly went NLA and you're stuck messing with used ones if needed.

:duck:
 
Oh nuts. Is the problem the ignition lock tumbler, or the lock mechanism that the tumbler goes into? The tumbler is still available new, VIN coded, from the dealer. But the lock mechanism assembly went NLA and you're stuck messing with used ones if needed.
It seems like the steering wheel lock mechanism is keeping it from turning. You know when you turn the ignition off and you can't turn the ignition back to on unless you remove the key first? It almost feels like that. It only seems like it wants to turn to position 1 but only turns about 1/4" and I can hear the steering lock mechanism inside snapping back slightly when I pull the key out. I'm wondering if I were to somehow remove the lock mechanism from the column and press the steering lock all the way in with my hand would it turn then?
 
I might have to order a vin coded ignition lock cylinder as well. I did snap the hardened face cap on the ignition where it spins freely now and I can align the holes with where they should be in the 1 position to remove the cylinder but I cannot get it to come out. Sigh
 
Well, that was a whole lot of fun! At least the original lock cylinder and electric switch is just fine. I ended up completely murdering the lock housing once I got it out to try and see what caused it to lock up. But I honestly have no idea what I’m looking at or what to look for. Also, even after turning to lock cylinder now to position 1, I still cannot get the cylinder and sleeve to come out of the housing. I’m using 2 nails that I ground down the tips on but it’s not working. I don’t have a coat hanger laying around. But I do have about 2 weeks until the replacement lock housing arrives. I’m sure I’ll figure it out by then..
 

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