Thanks for the info.
Its hard to believe a faulty egr would cause so much gunk in the intake.
The intake is now clean and the egr disabled.
What would be a good way to clean the sludge out of the head? Carburetor cleaner is the only thing I can think of.Would this be ok to use since it is a diesel?

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• 1989 Jeep cherokee 4x4 110k (sold)
• 1988 Porsche 924S 90k totaled
• 1988 VW Sirocco 16v 110k? (needs work)
• 1985 Volvo 745 Turbo 225k
• 1981 Mercedes 300D "Olga" 205k 100k on Mercedes factory reman motor