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  1. #1
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    Default My G-wagen with 642 engine, failure.

    On 3 November 2023 just after a game of golf and en route home the engine made a funny noise and lost power. I stopped and called a rollback as I realised there is major problems under the engine hood now. No info from the ECU whatsoever beforehand!

    My regular Indi that also owns the rollback started removing and stripping the engine the following week. Being out of MB warranty and with after-warranty with maximum benefit of R65k there was no other way to go. As per knowledge at the time. At first the oil was drained. The sump capacity is 12L and they drained 20 Liters! The oil was well diluted with diesel which was the obvious cause for the engine failure. Two big-ends and one main bearing was visibly seized and beyond repair.
    There was at this stage no idea why there was so much diesel in the oil. The injectors were sent away and all of them tested good. So over-fueling from that end was not on.

    Then came the shock when they started looking for overhaul parts for this engine. No aftermarket parts are available. Agents only. Then the second shock, not oversize parts available. Only standard sizes, meaning all affected parts need to be replaced with new. Now, in a situation like this one can appreciate that all components that is oil lubricated is suspect, even as far as cam bushes and beyond.

    The first quote from MB for basic parts came to R549479 (Excl VAT). This was not all required. A new sub-assy amounted to R780k! We started looking for a replacement engine and Japan Auto had one for R120k.

    Then my Indi told me about a gentleman that specializes in rebuilding MB cars and came well recommended. The good part is he was based 2km from my premises on the same street. I pass that place everyday and always wondered what happens there. Long story short, Reinold offered to replace the engine with a similar in kms and life for R169k, c/w six month guarantee. He just bought a GL350 write-off due to rear end accident damage. It did take some time to get everything in line with the two different bodies and small changes in the units that had to be sorted.

    And I was quite happy with his service! We are still friends!!

    Then I found the attached Centrix on a VW post on the 4x4Community thread. Specifically mentioning the possibility of diesel mix in oil due to DPF malfunction on the 642 and other engine models. This note was dated 2012! And I realised the reason for my engine failure. Dammit!!
    The DPF on my car was replaced under warranty by MB during December 2021 and as per their conditions such parts carry a 24 month warranty irrespective of kms travelled. I went back to my records and saw the engine failed in month 23! If only I knew of that Centrix at the time I could have claimed a new engine from MB. Albeit maybe after a good fight.

    I immediately asked Reinold to have the DPF removed and remapped accordingly, which was done during last week.

    For the first time since I bought it in 2017 (and after several limp issues that was never resolved) I am totally happy and trusting.

    Moral of my story? If you have a similar engine in your car have the DPF removed. ASAP
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    Johan Maree
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  2. #2
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    Default Re: My G-wagen with 642 engine, failure.

    Sorry for that ordeal.

    Honestly I don't think you would have had a claim against MB based on that DPF notice, it sights user error and not letting the DPF do its thing.

    On the Jeep we dont have the regen DPF, so seems we are safe.
    2007 Jeep Grand Cherokee 3.0 CRD Overland - GDE Eco Tune + 2" Lift on 265/70/17 BFG KO2's
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  3. #3
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    Default Re: My G-wagen with 642 engine, failure.

    Sho, that's quite a repair bill. I glad it all worked out in the end.

    two technical questions come to mind when I read your ordeal.

    1- with so much overfill in the oil, why did the engine not " run away" ie; refuse to shut does as the over fill of oil feeds its self when the fuel supply cuts off. This was an issue with diesel vw's a while ago caused by overfilling oil. Maybe there is a fail safe in place.

    2. I'm surprised the benz does not warn on the dash if there is too much oil. The Touareg will warn you on the dash if it detects too much oil.

    inevitably, its all the emission systems in place that made modern diesel engines tend to fail as in this case.

    Karol Life = Σ(Choices)
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  5. #4
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    Default Re: My G-wagen with 642 engine, failure.

    Make 100% sure you have correctly identified the problem.
    You don't say what parts were re-used from the old engine.
    My previous Pajero did that, and it turned out to be he seal where the diesel injector pump was attached to the engine.
    Fortunately I caught it in time.

    Watch the sump oil levels closely!
    2003 Mitsubishi Pajero 3.2 Di-d LWB

  6. #5
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    Default Re: My G-wagen with 642 engine, failure.

    Quote Originally Posted by Quiksilver View Post
    Sorry for that ordeal.

    Honestly I don't think you would have had a claim against MB based on that DPF notice, it sights user error and not letting the DPF do its thing.

    On the Jeep we dont have the regen DPF, so seems we are safe.
    On my car there is no notification at all that the DPF is regenning. You know nothing of the sort is happening or not happening. The original replacement of the DPF was to find the reason for the continuous limp issue, and not because there was anything wrong with the unit itself.
    Johan Maree
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  7. #6
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    Default Re: My G-wagen with 642 engine, failure.

    Ai man Johan - sorry to hear.
    Glad you sorted again, though.
    ......Not the first time that engine gave you kakkas, IIRC??
    Anyway - Groete daai kant!!!

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  9. #7
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    Default Re: My G-wagen with 642 engine, failure.

    Quote Originally Posted by Petri Oosthuizen View Post
    Ai man Johan - sorry to hear.
    Glad you sorted again, though.
    ......Not the first time that engine gave you kakkas, IIRC??
    Anyway - Groete daai kant!!!

    No limp at all since the swop which was done nearly 4000km ago.
    Johan Maree
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  11. #8
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    Default Re: My G-wagen with 642 engine, failure.

    That's really a bad one, so sorry to hear. I have the same OM642 engine in my GLC. What's the mileage on yours?
    Mercedes Benz GLC 350d

  12. #9
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    Default Re: My G-wagen with 642 engine, failure.

    A really nasty shock and I have long been suspicious of a DPF in any vehicle, almost instinctively.

    Could you share how the DPF actually caused the problem?

  13. #10
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    Default Re: My G-wagen with 642 engine, failure.

    Is the OM 642 the 320/350 Cdi which is actually a 3.0 litre V6?

    Iíve had a few of those and had no problems, in my mind quite a reliable engine.

  14. #11
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    Default Re: My G-wagen with 642 engine, failure.

    Quote Originally Posted by AwieT View Post
    That's really a bad one, so sorry to hear. I have the same OM642 engine in my GLC. What's the mileage on yours?
    Awie. The failure happened on 130003km. Last service by MB at 120k. I will really urge you to have it removed. We don't need this crap in our country. Cost me R4500. Best insurance premium ever.

    Quote Originally Posted by mudgrubber View Post
    A really nasty shock and I have long been suspicious of a DPF in any vehicle, almost instinctively.

    Could you share how the DPF actually caused the problem?
    I do not understand it myself. I hear that the fuel pump keeps on pumping if the regen is interrupted. I have no idea how the diesel finds itself going into the sump.
    Johan Maree
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  16. #12
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    Default Re: My G-wagen with 642 engine, failure.

    Quote Originally Posted by mudgrubber View Post
    A really nasty shock and I have long been suspicious of a DPF in any vehicle, almost instinctively.

    Could you share how the DPF actually caused the problem?
    its discussed here with an amarok

    https://www.4x4community.co.za/forum...o-high-warning

    video

    https://www.youtube.com/watch?v=lJtENVwAEpk
    Last edited by Karol; 2024/05/06 at 02:20 PM.

    Karol Life = Σ(Choices)
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  18. #13
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    Default Re: My G-wagen with 642 engine, failure.

    Quote Originally Posted by 4ePajero View Post
    Make 100% sure you have correctly identified the problem.
    You don't say what parts were re-used from the old engine.
    My previous Pajero did that, and it turned out to be he seal where the diesel injector pump was attached to the engine.
    Fortunately I caught it in time.

    Watch the sump oil levels closely!
    Only the oil filter housing as the G is equipped with a second oil cooler due to the power upgrade that was done on the 2016 models. There is an additional pipe on the housing for this purpose. And a new complete harness fitted.

    Power increased from 180kW to 210kW. Little monster now.
    Johan Maree
    Isuzu 3.0 DC V-Cross 4x4
    MB Gwagen G350 Bluetec
    Nissan NP300 2.4 4x4
    Conqueror UEV-25
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  19. #14
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    Default Re: My G-wagen with 642 engine, failure.

    Ek neem aan mens noem dit geseend. Want as dit nie vir daai man wat in jou straat bly sou jy moes diep grawwe in jou sak.
    GaryG


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  21. #15
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    Default Re: My G-wagen with 642 engine, failure.

    I have been thinking long about removing my DPF and even though our engines share nothing, this is making me consider it again.

    DPF regeneration cycle being interrupted causing the extra fuel going past the piston rings?
    "K.a.k Wheeler"

    Dont take anything I say as actual advice or fact. I dont.

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  23. #16
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    Default Re: My G-wagen with 642 engine, failure.

    Eina blikskottel!
    Maar darem nie so eina blikskottel as wat dit amper was nie!

    Hoop sy bollie is nou op 'n einde.
    Beat-up rat rod of a '96 Nissan Patrol that bears the evidence of many wonderful adventures (and a few stupid indiscretions).

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  25. #17
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    Default Re: My G-wagen with 642 engine, failure.

    Quote Originally Posted by JohanMaree View Post
    Only the oil filter housing as the G is equipped with a second oil cooler due to the power upgrade that was done on the 2016 models. There is an additional pipe on the housing for this purpose. And a new complete harness fitted.

    Power increased from 180kW to 210kW. Little monster now.
    Keep a beady eye on the sump levels, in any case!
    2003 Mitsubishi Pajero 3.2 Di-d LWB

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  27. #18
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    Default Re: My G-wagen with 642 engine, failure.

    Been following the G-Wagon's trials and tribulations and hoping for a resolution somewhere, somehow.

    While not perfect, it did cost a packet and a missed warranty opportunity, I'm glad to see the situation looking up.

    Wishing you lots more powerful and fun kilometers ahead Johan.
    "The problem with internet quotes is that they are very often unverified."
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  29. #19
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    Default Re: My G-wagen with 642 engine, failure.

    Quote Originally Posted by JohanMaree View Post
    Awie. The failure happened on 130003km. Last service by MB at 120k. I will really urge you to have it removed. We don't need this crap in our country. Cost me R4500. Best insurance premium ever.


    I do not understand it myself. I hear that the fuel pump keeps on pumping if the regen is interrupted. I have no idea how the diesel finds itself going into the sump.
    Ek dink ook so Johan, sal moet plan maak.
    Mercedes Benz GLC 350d

  30. #20
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    Default Re: My G-wagen with 642 engine, failure.

    So sad to hear Johan. sorry for this, as it is an awesome vehicle and I love working on these 642's

    What we have been finding a lot more these past few months, especially on the mercs and VW's, is tuners only deleting the fault codes, and the actual module and also not removing the DPF hardware. This is dangerous!!
    firstly, if ou don't remove the hardware, the DPF will clog up and cause a lot of back pressure.
    secondly you wont know it, as there will be no indication of the part failing as the ECU will not through a warning.

    maybe send your ECU to Mike in Silverton and let him read the software on it.
    might be that someone has tampered with it, and did only half a job.....

    I do a lot of these Merc on a weekly basis, and I redo a lot of them that was done by other guys, supposedly cheap cheap solutions.

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