Air Inlet Hose repair

1986-1995 : 200TD, 200CE, E200, 260E, 300E 2.6, 300E 2.8, 300E, E320, 400E, E420, 500E, E500, 300CE, E320, 230TE, 300TE, 300D 2.5 TURBO, E300 DIESEL, 300TD, 300E 4MATIC, 300TE 4MATIC, E36 AMG
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dhaigh
C Class
Posts: 40
Joined: Fri 12 Aug, 2016 3:05 pm
Model you own: w124
Location: Melbourne, Australia
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Air Inlet Hose repair

Post by dhaigh » Mon 09 Apr, 2018 11:14 pm

Many owners of W124 cars with the M103 engine (2.6L, 300E, 300CE and 300TE, 1986 – 1991) will be suffering from either a broken air inlet hose or one that is completely missing. These have suffered the ravages of time, from burly mechanics with fat fingers that break the flexible ‘concertina’ hose when removing the hose without first removing the air cleaner assembly. (Note to owners: the concertina hose is very fragile after 30 years and should never be removed without first removing the air cleaner assembly, complete with hose attached, and removing the hose from the assembly when it is on the bench). Some will have been poorly repaired in the past.
Damaged hose w text.jpg
The bad news is these hoses are no longer available new – either online or from Mercedes. A couple of months ago, I did locate a new one still available on the shelf of an online parts store in America, but they wanted $55 USD plus $75 USD postage – too expensive!
The good news is these can be repaired ‘as new’ again for around $20. Here is how:
The W126 air inlet hose for the M103 engine (300SE, SEL) is still available new, from Mercedes Benz, at a cost of $20, and the concertina section from that hose is exactly the same profile and length as the W124 hose. So, firstly, order a W126 hose from your local Mercedes dealer (Part Nbr 103 090 04 82).
1. New W126 hose.JPG
Air hose 103.981 300SE W126 c.JPG
Cut the damaged concertina section from your old hose and then cut the required length from the new hose to fit appropriately. This should be done along the valley of one of the concertina ‘V’ sections, in order to hide the join – use a Stanley knife and take your time. Also, measure carefully to ensure the finished hose will be the same length as the original. Clean the inside of the old hose thoroughly. Match up the new concertina section to your original oval section and ensure a good fit, and then use masking tape to hold the 2 halves firmly together.
IMG_5706.JPG
2. Hose ready for gluing.JPG
Next, cut the required length of medical Micropore tape (available from a Pharmacy), to fit around the INSIDE of the hose. I recommend you cut 2 lengths and do one half at a time, as it’s easier. Apply a liberal coating of JB Weld Plastic Weld (eBay $16.95 free postage), or similar epoxy resin, to one length of tape and place it inside the hose where the join is located. Press the tape down firmly with your finger or a wooden stick (an ice cream stick is perfect) and the epoxy will ooze through the absorbent tape making a good strong join. Repeat for the second length of tape.
3. Tape on the inside of the hose.JPG
If you get epoxy resin on the outside of the hose during this operation, it can be removed with paint thinners or acetone before it dries. To protect your fingers from epoxy resin, you can wear latex gloves.
Allow to dry overnight, and Hey Presto – perfect ‘as new’ air inlet hose for $20!!
4. Repaired hose.JPG
If your air inlet hose is currently missing from your W124, and you don’t have one to repair as above, the W126 hose (oval section) will fit perfectly on your air cleaner assembly, but the other (circular) end will not quite reach the air duct beside the radiator (it will position just behind the headlamp cover assembly, but that is better than not having one at all).
Alternatively, if you cut and remove the W126 concertina hose near the oval end, there are plenty of flexible hoses you can buy and fit that will reach the air duct. Black flexible hose from Bunnings is a perfect fit.
End Note: If you want to buy a repaired hose, in 'as new' condition, I have some available on an ‘exchange-basis’ for $50 (or $70 outright). Contact me for details.
David Haigh (0412550020 or email da_haigh@bigpond.net.au)
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Last edited by dhaigh on Tue 19 Jun, 2018 9:12 pm, edited 1 time in total.
1988 300CE Coupe
Departed:
1989 300E
1990 MX5
1966 Ford Fairmont
1954 Healey BN1
1972 E-Type V12
etc
See my website: http://myclassiccars1967to2017.blogspot.com.au/ for the complete list!

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Ivanerrol
Mercedes Demigod
Posts: 5782
Joined: Sat 12 May, 2007 3:21 pm
Model you own: w204
Location: Melbourne

Re: Air Inlet Hose repair

Post by Ivanerrol » Tue 10 Apr, 2018 9:44 pm

Question without notice :hand:

Why is it that MB discontinues the M103 W124 inlet but continues on with the M103 W126 one? :whistle:
W211 - E240
W204 - C280
Departed
W202 - C200, C180, C180
W126 - 380SE , 380SE (Ex SA Import), 560SEL
W124 - 300e, 260e (ex Japan)
W111 220s (Indonesia) 4 speed manual column shift
W123 230
W116 450SEL
W140 420SEL
W210 E240, E240
W209 CLK 240
W201 190e 2.6 (ex U.K.)

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dhaigh
C Class
Posts: 40
Joined: Fri 12 Aug, 2016 3:05 pm
Model you own: w124
Location: Melbourne, Australia
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Re: Air Inlet Hose repair

Post by dhaigh » Wed 11 Apr, 2018 10:40 am

Ivanerrol wrote:
Tue 10 Apr, 2018 9:44 pm
Question without notice :hand:

Why is it that MB discontinues the M103 W124 inlet but continues on with the M103 W126 one? :whistle:
Good question (without notice)...the W124 hose has been NLA for about 9 months and I suspect when stocks of W126 run out, that will be it for the W126 as well!!
Mercedes was never very common (sense) was it??!
1988 300CE Coupe
Departed:
1989 300E
1990 MX5
1966 Ford Fairmont
1954 Healey BN1
1972 E-Type V12
etc
See my website: http://myclassiccars1967to2017.blogspot.com.au/ for the complete list!

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Bartman4800
300 SLR
Posts: 1851
Joined: Fri 10 Oct, 2008 12:10 am
Model you own: w111
Location: Perth WA

Re: Air Inlet Hose repair

Post by Bartman4800 » Thu 12 Apr, 2018 4:30 pm

Sounds like a good candidate for 3D printing....


Bart
1963 220 Sb Sedan "Kermit" (Australian Assembly)
1960 220 Sb Sedan "Zum Schlachten" (Early German Assembly, with a torsion bar spring for the bonnet) - Stored in Country WA
1981 Subaru Brumby 1.8 with Weber and 5-speed box "little utie" - Sold to another enthusiast!
2006 Ford Focus "daily driver"
2002 VW Passat V6 30V Station Wagon (SOLD - This car into a money pit)
2011 Kia Sportage "Missus commuter Bus"
2002 Mitsubishi Rosa Bus (converting it to a motor home)

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MMWA
450 SEL 6.9
Posts: 470
Joined: Sun 08 Dec, 2013 2:23 pm
Model you own: I own multiple different models
Location: Perth

Re: Air Inlet Hose repair

Post by MMWA » Sun 15 Apr, 2018 11:42 pm

Don't know what the JB weld stuff is like, but from experience most epoxy resin goes yellow, brittle and breaks apart when exposed long term to engine bay temperatures.
MMWA

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dhaigh
C Class
Posts: 40
Joined: Fri 12 Aug, 2016 3:05 pm
Model you own: w124
Location: Melbourne, Australia
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Re: Air Inlet Hose repair

Post by dhaigh » Thu 21 Jun, 2018 12:07 am

MMWA wrote:
Sun 15 Apr, 2018 11:42 pm
Don't know what the JB weld stuff is like, but from experience most epoxy resin goes yellow, brittle and breaks apart when exposed long term to engine bay temperatures.
JB Weld is formulated for plastic. The epoxy is on the inside of the hose and since it is near the air scoop, will be drawing in lots of lovely cool air. I suspect if the engine bay was hot enough to cause the epoxy to breakdown, then I suspect the hose will melt first followed by all your wiring!!!


Last bumped by dhaigh on Thu 21 Jun, 2018 12:07 am.
1988 300CE Coupe
Departed:
1989 300E
1990 MX5
1966 Ford Fairmont
1954 Healey BN1
1972 E-Type V12
etc
See my website: http://myclassiccars1967to2017.blogspot.com.au/ for the complete list!

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