Fixing Black Death on my T1N Sprinter!

In this video, Bill & Mike tackle the infamous Black Death! Contrary to the name, it is not the death of your engine and with some patience, you can transform this tarry mess into something so shiny you'd want to eat off of it!
Also petitioning to change the name to injector seal leak (ISL)!
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AMAZON AFFILIATE LINKS
Autel AP200: amzn.to/3h2gLY0
Anti-Seize: amzn.to/39Hd6xw
Oven Cleaner: amzn.to/2JPApdA
Inspection Mirror: amzn.to/3lI90rt
Hook Tool: amzn.to/3qpMHdP
Green Scrubby: amzn.to/37HC6Cu
Gloves: amzn.to/2JMpfq7
Shop Towels: amzn.to/37EXR5w
Injector Extractor: amzn.to/3mNOdEc
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MMS LINKS!
Stretch Bolts & Injector Seals: www.millionmilesprinter.com/p...
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Audio Credits: bensound.com

[@svenl.3314]

Linked Timestamps for 'later' when fixing 'Black Death': 0:30 Materials 3:00 Cleaning I 8:10 Pulling 15:24 Cleaning II 18:46 Reinstall

[@Ironman95246]

Tip that I learned from Doctor A. Run the van unti its hot, whilst spraying WD40 down on top of the injector. After its hot and lubricated Unscrew the injector bolt 3 turns. Then drive the van a bit until the injector pops up and out a bit. You’ll know by the sound. He told me the hot engine makes the carbon stuff a liquid and the pressure will pop the injector up and out for you. Then you unscrew the bolt the rest of the way and take the injector the rest of the way out.

[@ChrisKoski-bi9rg]

This technique is a huge time saver, did it this afternoon for 2 injectors, took just 1.5 turns and a short drive for them to pop up. Thanks for the tip!

[@gerhardpfeifer6930]

You guys are awesome! Good job! Thanks for the information.

[@craigholliday3907]

thanks so much, bought mine with the black, thanks for the great content... keep it coming

[@skeight976]

great video, I am about to remove my cover once, I get the intercooler and A/C condenser back on. my videos on that will be out tomorrow. thank you so much for making these videos. great detail!

[@WingItWithEthan]

Oh, boy I’ve never checked this on mine. Thanks for the video Bill and keep up the great work brother!

[@ems1mc]

It’s good to hear that exact same sound we were having on the road. Now I can confirm that there is an injector leak for sure.

[@vincentrolfe1384]

If you take one of the stretched injector bolts and grind a bevel on the end, that can be used to clean up the bolt hole threads in the head. Just a light handed approach and screw in until resistance is felt and back it out (wipe of the carbon) and try again numerous times. Then when you put in the new bolt is goes in with no resistance.

[@go5582]

Great comment

[@vincentrolfe1384]

@@go5582 Thanks FVM. I had a problem recently with voltage drop from the short negative battery cable. Van no start. Replaced cable and now at 190K I am all smiles. Before finding the neg cable problem I replaced the ignition switch as the dash was not lit. Made a special tool of welding wire (mild steel) to reach around on the back side of the switch barrel to release that little locking pawl and the switch came right out. Will do a vid on that at Vincent Rolfe (utube) when the Chicago weather quits being -5F as it was today. Can you bottle a little of that FLA air and send it to me??? Price on T1N parts is going down as MB is not moving their inventory stock and it is costing more to house slow movers in their warehouse. Replaced the passenger side wide angle mirror for 30% less $$$. Time to buy some T1N stuff on sale in isle 6 at Walmart-MB.

[@Masterryman]

I had this too on my Sprinter but Aucar in Wittlich Germany fixed this and since its running well. Dont wait to long, its horrible mess

[@vincentrolfe1384]

My #2 cylinder had the death and I made a series of welding rod chisels along with using an old wood chisel and finally after 3 hours got the mess around the injector cleaned; then, I removed the injector with lots of back and forth along with oven cleaner and more chisel work. patience is the word. Your 2500 was driven lots of miles with that leak. NO vac used just dampened paper towels on the end of long shaft flat blade screw drivers.

[@462904]

Boss vid boys great job hats off 👍🏻👏🏻👏🏻👏🏻👏🏻

[@bobd3330]

Nicely done Tampa check in

[@DaveBerryQualityFireplaces]

Purchased new in 2006 and with 186000 miles I thought I would take a look under the cover. Looks like it left the factory a week ago. Very reassuring…. Many thanks for the videos. I’ve managed to change many parts over the last few years and with me being a body repairer and sprayer the now converted camper van looks and drives superb…..

[@timborgenheimer155]

My 2006 has 450000 still runs perfect. Amazing how well this engines are made.

[@bennytdi]

This is exactly what my Landrover Defenders sounds like. Thankyou so much for this video.

[@FloridaVanMan]

Funny true story: As I walked into a store one day I heard the familiar acceleration of a 5 cylinder Sprinter, so naturally I turned to look. I was confused by the sight of a LandRover and my mouth must have been actually open as I wondered how this ugly truck sounded like one of my babies. The driver thought I was admiring it, so a conversation ensued. I did not tell him his duckling was ugly. To him it's a swan, and whatever foul bird it really is... it has a heart of gold. "Team 5cyl"

[@80sDweeb]

I'm not ready to do it, so I haven't removed the cover and taken a look yet. Great video, nice tips on the necessary tools!

[@skeight976]

I dont want to look at mine.

[@TaylorThoughts]

Great video

[@nunyabusinessfriend]

Good stuff!

[@coskunbahceci]

Thanks for the video.

[@gurpreetgill2250]

Thanks for video mate, may be someone have answer to my problem. I have Mercedes Vito 2003 recently changes high pressure pump seals. Used little bit too much 😜 starter fluid to start Van not engine is running very roughly and white smoke coming out exhaust. Any suggestions please

[@yahoo2020]

Thanks guys I pulled my injector today and got it all cleaned up, I mainly used rifle cleaning kit for the bolt clean out, Thanks again I couldn't have done it without you and who knows how much money I saved

[@FloridaVanMan]

That's the idea! We want to save you enough money that you feel compelled to make a donation and help keep new videos coming. We've been turning out fresh videos every week, granted some are better than others. Please help us keep it going. floridavanman.com/donate/

[@gregboyd4321]

Dang thought I was going to see a good old Friday night grease knuckle busting movie on how to get #5 & #4 cylinder injector out. U make it look to easy. Give those boys a big cigar and a coffee. ;-)

[@Andreyhappy74]

Respect guys 👏👏✊🤝

[@go5582]

God bless you,assistant and the germans for building a beautiful vehicle. You guys are fun and very special. Thanks your parents for me. I have a question I'm getting into the van life and I'm debating which van to buy , a 2002 Chrysler/Mercedes/freightliner sprinter 2500 Diesel or a 2023 all electric Mercedes sprinter? Which one should I buy? Please explain why?

[@Timothyis]

You existing is Good. 💛

[@krakenwoodfloorservicemcma5975]

Absolute madness.

[@FloridaVanMan]

A few months later and this van is still killing the game, and just as clean as it was at the end of this video!!!

[@krakenwoodfloorservicemcma5975]

I know you do good work and I agree the sprinters can be good vans.. I have had one 15 years.. I only get down on them because the tech level is way over the avg owner to do any diagnostic repairs. You seem to like the work and that’s cool, but for me? I just want a reliable machine so I can go do my idiotic flooring work. Most dealerships can’t even troubleshoot these that well.. I know some can but it’s a crapshoot for the owner that lacks knowledge.. I repaired diesel locomotive electrical systems for 12 years and I am certainly burnt out of fixing stuff.... or I got lazy) keep up the good work and continue to help whom you can. It’s needed.

[@adellofrattelo3463]

Nice Video

[@zambotv8150]

Because I lack, patience, patience, patience I take it to a guy that services a fleet of Sprinters, it's one of the few jobs I really don't want to do on my van/s, I have replaced front crossmembers, rockers etc, injector pulling? No chance

[@georgecormier601]

How could you tell which injector was bad ?

[@super-bn5xz]

Flat side of the copper seal on the injector (steel) rounded side to the engine (aluminium) 👍

[@FloridaVanMan]

Yes, although OEM washers don't have a flat side. I don't buy theses knock off washers with flats any more.

[@mihaicarpiuc2252]

Super, wou gut giob profesional

[@OneManOnFire]

My back hurts watching this video. What way points up on the copper washers? One side was dome shaped and flat. My diesel experience comes from 1981 W123 and we prime the system after fuel work. Will this one need priming?

[@FloridaVanMan]

I'm not clear about that. Logic tells me the flat side should press to the steel injector and the rounded side will seat to the aluminum head. Maybe others will comment to confirm or refute my thoughts on this. The ones I am accustomed to do not have a flat side.

[@dke186]

Having replaced the #3 injector, is it worth the effort to preemptively replace the seals on the other injectors? Or is fixing them one-at-a-time entirely sufficient?

[@FloridaVanMan]

We have mixed opinions on that. I feel it is best to leave good seals alone. I can't fix it if it ain't broke, and replacing a good seal may end in disaster with a stripped bolt hole or a new leak that we didn't have earlier.

[@offset25]

@@FloridaVanMan the bolts seem to come out fine when I try to remove them and they go in just as easy and the torque isn’t to bad to put on it. But even with that said there is a risk of still stripping them?

[@lolipop9897]

When i had black death on my vito, i only had patience and patience and i got it to assembly point and I cracked the treads then i snapped and towed it to an garage.

[@FloridaVanMan]

Oh yea! Patience and patience is not enough... You also need More patience! LOL This is one job that any amount of "hurry" will cause error! And those errors can be a killer. Did you see the later video where the bolt broke in the hole? That is even worse than stripped threads because I had to drill the steel bolt out of the aluminum head before tapping new threads.

[@ozoz420oz]

75000 people with the same mundane problem

[@MrCanadascott]

I see you pressure washed after. Is there a reason not to pressure wash right at the start or compressed air.

[@FloridaVanMan]

I found pressure washer doesn't do much to the carbon except get it wet. Then the oven cleaner is less effective. Shop vac is highly recommended over compressed air. Blasting with air throws the carbon debris *somewhere, and there are many exposed places we don't want it. Getting all the water out of the injector area after washing is critical. A leaf blower or compressed air is fine for this, but shop vac also works wonders here. Warm to dry the engine lastly, before installing the plastic engine cover.

[@fuffoon]

You don't have to wait until they are carboned in and stuck. Re-seat them every 50k miles as a routine.

[@FloridaVanMan]

Every 50k would excessive. Common practice is to remove them at 200k for testing and of course new seals & bolts when reinstalling. Have injectors tested for $25 each at a Bosch Authorized Service Center any time the injectors are out of the engine.

[@remyfla6858]

Bill, any video on removing a Glow plug that's just free spinning?

[@FloridaVanMan]

Glow plug video is in the works, but not here yet. Sorry.

[@remyfla6858]

@@FloridaVanMan NP I have a recently purchased 2006 with ENG light constantly on and it codes to the two front glow plugs which are free spinning. I bought my mech a kit to remove it and he reluctantly backed out claiming it was too easy to ruin the head.

[@lorenzodeangelis8463]

So just to clarify you don"t need to cut / ream the seat if you can properly clean and remove all the carbon from the seat? Is there another reason for reaming the seats?

[@FloridaVanMan]

I've not found any good reason to ream a seat. Seat cutters in the hands of unsupervised DIY-Guy often leads to chatter marks and bigger problems. Use scrubber pads, not wire brushes because brushes drop bristles that end up inside the engine. Scrubber pad on a spinning disc will do almost everything a seat cutter can... without the danger of going too deep or creating bigger scars.

[@OneManOnFire]

For me #4 was leaking and stuck according to the Dodge dealership who used a cherry picker on the injector itself. This was when I bought it from the last owner. It was running poorly and stripped treads on the #4 hold down screw according to my mechanic. My mechanic removed the valve cover and used a helicoil to repair the threads. Cost me $1,500 (labor, anti seize, cleaner, injector washers, valve cover gasket, and new bolts) in total and I provided 1 new injector. How hard is it to fix stripped treads on the hold down screw?

[@zambotv8150]

It depends on how good the access is, taking 4/5 injectors out from one of those engines is a whole load of work

[@FloridaVanMan]

The front holes are not too bad. The back holes are a real pain but can be made easier by pulling all the plastic air ducts out from above. The hard part is drilling and tapping the hole straight, without overhead room. Lifting with a cherry picker is limited to the weight of the van. The proper puller pries against the block of aluminum the injector is stuck in, rather than lift the van.

[@buffhooper7417]

Wow

[@undeadtacticalsquad]

What size screw driver did you modify into the hook tool?

[@FloridaVanMan]

I know they come in different sizes but this was just an average "regular size" cheap screwdriver.

[@375dirtrider]

does this always require cleaning the threads?

[@FloridaVanMan]

Yes, any crud left in the bolt holes will cause the bolt to tighten before it clamps down the injector. When the injector is not held tight the seal will leak causing new case of black death.

[@christopher6161]

any secrets to power washing it without damage at the end?

[@FloridaVanMan]

My pressure washer is not the biggest-baddest, and I use a fan tip. But I go crazy and never had a problem. Under the hood, under the van, under the driver seat... Yea, I did it!!! I don't recommend it, but I did it more than once and have not had a problem.

[@lolipop9897]

18:49 mmkay

[@1jeepinray]

Hi just asking about the coding, are you saying the computer adapts to the new injector without being reset ?

[@FloridaVanMan]

Not exactly. The computer adapts to maximize performance. The coding gives the computer a starting point for that adaptation. But it is more complicated than one value adjusting up or down because there are 6 values in the coding addressing 3 stages of the injector, timing and duration of each.

[@michaelkeever2761]

@@FloridaVanMan thanks for the vid. I've got to check mine. I smell exhausted in the cabin when I the heater.

[@nickngaopraseut6717]

Is there a specific reason you don’t use an pneumatic air blower to clean the area?

[@FloridaVanMan]

Yes! When blowing debris away... where does it go? I don't want it going in my engine or my eyes, mouth, nose, hair, etc.

[@manuelortiz7731]

What were the symptoms you were having with the black death?

[@FloridaVanMan]

Removing the plastic cover over the engine you can see it, but it doesn't always cause a driving problem. The first symptom is often smelling fuel in the cab, then hearing a chuff-chuff-chuff under the hood. If ignored the van will keep going, but the mess gets bigger and harder to clean up.

[@theeaskey]

Where in fl..and do ye work on t1n sprinters...

[@FloridaVanMan]

Between Daytona and Orlando. We work on Sprinters when we are confident the troubles are within our scope and abilities. We don't have a shop and don't want to become mechanics, but we know the T1N Sprinters better than any mechanics around and do everything we can to earn your donations. floridavanman.com/donate/

[@Simonofcalifornia]

Transit here I come.

[@FloridaVanMan]

Injector seal leaks could happen to anything to be fair.

[@Simonofcalifornia]

@@FloridaVanMan I’m just being an ass. Saw a 2008 sprinter with 720k miles on original engine last week.

[@theeaskey]

Good luck install brakes on the transit..

[@richj8992]

If reusing an injector what would you use to clean it? Brake cleaner and a greenie?

[@FloridaVanMan]

Yes but avoid the tip. Brake cleaner and scrubbie, avoid wire brushes or anything with fit that might fall off, like sand paper or steel wool. Scrubbies might shed and teh shedding is abrasive, but not gritty.

[@richj8992]

@@FloridaVanMan thanks. I also have scrub pads made for nonstick pans, I'll start with those.

[@vincentrolfe1384]

FVM got some questions. I have a seat on the #4 inject that is leaking. Not much black death in the area but the hold down will not release after I removed the one time T40 bolt. Any idea as to what is keeping that hold down from coming out. I have been soaking the area with oven cleaner and have used 5K towels. I have tapped the small end of the hold down and sides too with little movement. If I can get the hold down off I will bring the motor up to temp. What is a source for the slide hammer injector remover? My first injector 35K miles ago was so easy to remove but I will need a federal court order to remove this one. Thanks

[@FloridaVanMan]

We have found J.B. Weld under more than one engine cover. it seems if the valve cover gets a crack, that is everyone's go-to product. The slide hammer-claw: amzn.to/2WfEfmP

[@vincentrolfe1384]

@@FloridaVanMan Well thanks for the response. I went ahead and ordered a slide puller from Amazon for the 320 MB. not enough room above 4 or 5 cylinder to run the slide with the furnished bolt that connects from the claw at 200MM (16 X 1.5 bolt) so have ordered a 90MM and 120MM bolt to make it work. That #4 injector was certainly hard to remove due to the hold down being frozen in the black. Went door to door up and down the block asking all the neighbor ladies for this oven cleaner and soaked the hold down for a day. When I get the shorter slide bolts dwill give it a shot. Govoni-Italy makes lots of nice pullers for Euro Diesels. The US made claw I got was a nice fit with no grind required. Have a good summer FVM and keep the stretch bolts comin!!

[@offset25]

@@vincentrolfe1384 where did you get the 90mm and 120mm? Also is it safe to spray oven cleaner down the shaft of a stuck injector? What about pb blaster will that be safe to spray down the shaft as well? I have a stuck injector so what to try both and want to make sure it’s safe.

[@nohemirolfe3487]

@@offset25 Dino, yes some of those spray cleaners are OK to soak a stuck injector or hold down arm. I, here in Chicago, can buy those bolts or go ahead and order on the net and get in a day or so. Due to the tight surroundings of those injectors I found the different lengths necessary so as to removed injectors. Hope this helps. If you see Diesel spray on your windshield; it's time to start looking for a leak. Some leaks have a slight metallic noise at first that develops into a leaking under compression sound.

[@gregboyd4321]

How is the set placed on the injector as it has a slight bevel to it?

[@FloridaVanMan]

The seals I am familiar with are beveled on both sides, so it does not matter which is up. I recently bought some with a flat side so I will need to figure that out soon, which side goes up. If you find out please let us know.

[@gregboyd4321]

@@FloridaVanMan will do. I bet million mile sprinter.com would known. Did u purchase from him?

[@ricky302v8]

13:42 'The extractor uses the valve cover as leverage' is that the same valve cover 9:45 that can easily be damaged if you put too much leverage on it?

[@FloridaVanMan]

The extractor presses on the valve cover where it is directly supported by the engine head at the brim of the injector hole. The valve cover is not supported anywhere else except the outer edge, so anywhere that makes an effective leverage point is also a brittle aluminum bridge.

[@anbimohamed3890]

What solution to use to break carbon outside the injectors

[@FloridaVanMan]

Good oven cleaner is the best I have found, not dollar store oven cleaner.

[@expomedia_]

I would like to get in contact with y’all if I could… I need to have several things done to my 2005 Dodge Sprinter

[@FloridaVanMan]

Try email to Bill at FloridaVanMan with the natural Dotcom ending. I'm careful not to give it to the bots so I won't spell it out here. Or add a detailed note with a small donation floridavanman.com/donate/

[@patienceisalifesaver9582]

My van idles good but shuts off randomly while driving can it be a injector issue

[@FloridaVanMan]

Randomly* or approaching stop lights and signs? Probably not injector issue but it is possible one is causing a fuel pressure issue. More likely the fuel rail or high pressure fuel pump. When was the fuel filter replaced?

[@megadeal]

Oooooohhhh noooo, Ohhhhh noooooooooooooooooooo,

[@LEXICOGRAFFER]

About the 5 minute mark: air compressors illegal in Florida, right?

[@FloridaVanMan]

I'm not sure what you mean. My neighbors get upset when I use air-tools and I don't use air compressor to blast dirt out because I am concerned about where the debris goes. I don't want it in my engine, my eye, or my mouth, so the shop vac does the job others may use compressed air.

[@jesuscoronaibarra1908]

Were are you i need a diésel mecanic

[@FloridaVanMan]

I am right between the world's most famous beach and most famous mouse (Daytona Beach & Mickey Mouse). But I'm not a real mechanic and only learned about Sprinters from 18 years of fixing my own mistakes. If you have a T1N Sprinter YOU are your best mechanic and I can help guide you through most common troubles our vans will have. All visitors must be members of our support group so joining is your logical first step to scheduling an appointment for visiting or online help with your van. patreon.com/Florida_Van_Man?Link&

[@grantdubridge7995]

Thanks for the video. Not quite as easy as I was told by the guy who sold me this T1N. Why don't you use mechanic penetrating oil? I sprayed my leaking injectors with Blaster and it seemed to dissolve the black pretty easily. It isn't like the one you are working on though. That was disgusting

[@offset25]

Is there any issue with blaster damaging the engine if you spray it down the shaft of a stuck injector?

[@grantdubridge7995]

@@offset25 of the injector is still stuck in the hole then the blaster doesn't get into the engine. I use a shop vac with a smaller hose, like a vacuum line size, to suck out the black death and liquid.

[@offset25]

@@grantdubridge7995 I ordered the pb blaster. Is it the same as carb off? Or different? I was able to loosen the injector bolt and drive the car around and that loosened it after 2 minutes of driving. I immediately stopped and once I heard it pop and leak fuel and retightened the bolt and drove back. I was then able to get the injector out. I actually found two seals in that injector. One caked black and attached flush to the top of the shaft it goes into. If you weren't paying attention you would have thought it was part of the injector which was also partially caked black. The other seal was at the bottom of the bore. The last person who replaced the seal didn't notice the existing seal already attached to the injector. I just bought the sprinter so I was doing all the fixes.

[@grantdubridge7995]

@@offset25 Pb Blaster it's a penetrating oil to remove rusted bolts and other stuck situations. I believe it has a lot of citric acid in it but don't really know. It does not have the Flourocarbons that carburettor cleaner has or the alcohol that brake cleaner has.

[@faraisamanjeyese6172]

I thought u would blow the pipe be4 fitting it on new injector

[@FloridaVanMan]

Do you mean clear the fuel lines? That is a good idea to ensure no debris gets washed into an injector. Thank you for tuning in and sharing your ideas.

[@normski262]

nightmare

[@FloridaVanMan]

If you dream of dragons, become a dragon slayer and change your nightmares into victorious battles.

[@mangasingh8050]

It's looking good lack nice to hear I want see people's power Will win soon

[@LeopoldoManuelRamirezMena]

what is that, burnt diesel?

[@FloridaVanMan]

Yes, the black crust is wet combustion gasses forming a hard carbon as it cooks and dries on top of the engine.

[@LeopoldoManuelRamirezMena]

Hmm... so, if leaking happens, we should see, wet parts there and then the crust starting to form? Or wet and liquids is a red sign and the crust will come days after? 😢

[@FloridaVanMan]

Wet is fresh leak. When the engine gets hot it will cook the wetness into a crust. As the wet vapor keeps coming, the crust keeps growing. @@LeopoldoManuelRamirezMena

[@lkny1999]

Hi

[@cringuscristian8970]

why not clean first ?.......

[@FloridaVanMan]

No doubt it should have been cleaned MUCH better before taking things apart. I think this was our first video on Black Death and we have many more as we learned to deal with this better.

[@systemofayeup-notatribute8553]

You'll never get the bits out with a vacuum. Use an air blower at every stage, and most of the injectors will pop out ok if you drive it a bit, destructive puller is absolute last resort unless you've got plenty of cash to waste.

[@FloridaVanMan]

We showed how it worked great with a vacuum on video.

[@systemofayeup-notatribute8553]

@@FloridaVanMan How do we know the bits were all out, there's allsorts of nooks in there. I tried a vacuum myself, then an air blower, the shit that came out after that.. A good way as it will blast some of the carbon off also.

[@FloridaVanMan]

@@systemofayeup-notatribute8553 I cannot advise blasting air into the thread holes causing that dirt to fly out. Canned air or air-compressor nozzles have worked for some. The vacuum and plastic straw is very effective and safer for you eyes and your engine. I use the straw as a depth gauge, ensuring the hole is deeper than the bolt. Small brushes are available everywhere now with reusable straws becoming popular. They work well for cleaning bolt holes too, but don't put them back in the kitchen. :O) Sometimes an injector can be popped out by driving. We tried running the van and putting a load on the engine, but going out on the road is not always an option, though it may work for some. Driving the injector out can also put you in a bad situation trying to get the van back home to clean everything up. Driving home on 4 cylinders isn't good advice. Replacing the popped injector roadside isn't good either, as there is no way to clean as well as we can at home. Thank you for the input. While we may not agree what is a "good idea", your suggestions have worked for other people and I'm not going to call them a "bad idea". It's just something I can't recommend because of the other problems that *might come with it. The destructive puller is definitely a last resort, but we can get Bosch Authorized rebuilt injectors for about $300ea.

[@offset25]

@@FloridaVanMan when trying to drive it out does the bolt need to be all the way out or partially loosened? Same with the bracket clip? The fuel line and return line I assume stay connected while doing this? I was thinking just driving around the block several times to loosen it.