One simple way is to make a solid "gasket" from a piece of sheet metal (even a Coke can will work) and place it in between the EGR valve and the intake manifold. That will retain the car's appearance while defeating the EGR function. The intake manifold will no longer see carbon-loaded exhaust and, if you remove and clean the intake, will stay clean.

Another simple way is to block the vacuum line to the EGR valve, thus preventing it from operating. Blocking the vacuum line is as simple as inserting a 'BB' in the rubber jumper that connects the plastic vacuum line to the metal nipple on the EGR valve.

Both of the above procedures are unobtrusive and might even pass an inspection. Caveat: my state does not inspect so you should get an opinion from forum members in states where inspections are performed.

A more extensive removal involves a kit that one of the forum members sells. It allows you to remove the EGR valve from the engine and cover the holes in the intake manifold and the exhaust pipe.

Finally, you can remove the vacuum valves from their place (usually on the left inner fender) in the engine bay and plug/remove the various vacuum and vent lines. It goes a long way towards cleaning up the look under the hood.

I recommend labeling all of the parts and pieces and documenting your work so that you can reverse it if it ever became necessary.

I don't know if there is a one-size-fits-all DIY since there are so many versions of the EGR system. There are many threads talking about EGR removal. I suggest searching for them and seeing what information and pictures are available.

Jeremy

__________________

"Buster" in the '95

Our all-Diesel family
1996 E300D (W210) . .338,000 miles Wife's car
2005 E320 CDI . . 113,000 miles My car
Santa Rosa population 176,762 (2022)
Total. . . . . . . . . . . . 627,762
"Oh lord won't you buy me a Mercedes Benz."
-- Janis Joplin, October 1, 1970