Is there something other than one allen bolt and two 10mm bracket bolts that holds this in place?
(There isn't but it will not be easy if it has been a long time since the crossover / switchover manifold was separated from the mixer housing)

Background:
I purchased a 95 e300D a month ago that all of the sudden started idling rough and shifting hard...so, as per everything I've been reading here I started out to test the vacuum lines with my brand new MightyVac and printed DIY info.

SIDE NOTE:
In order to have as much information on this car as possible I purchased the EClass Owners Bible, W124 Owners Workshop Manual, a subscription to alldatadiy and am rather underwhelmed by the lack of information especially on the vacuum system and glow plug elements. I also purchased whatever was available on the MB site a week ago and hope that those items will have a bit more teeth to them.

I've wanted to check and run new vacum hoses anyway (plus check fuel lines and replace filters etc...)

Testing of vacuum:
22-23hg at the brake booster and 5hg at the line that apparently goes to the transmission xxx (something I can't recall right now but I know I read it in a thread here), climate control etc...

Unfortunately, one of the hard vacuum lines that connects to a green diaphragm looking item (again I can't recall which part this is specifically but I'm sure I read about it here in the last few days) under the manifold area came apart and the nightmare began.

I download an alldatadiy sheet that showed an allen bolt and two 10mm bracket bolts were all that was needed to remove the resonance switchover but it won't budge. I have looked everywhere using every terminology I can think of to find the answer so I'm hoping someone can tell me the step I'm missing to be able to remove this particular manifold.

In attempting to reconnect that one another line separated itself etc... I was finally finally finally able to reconnect the various lines by reaching "in up under" (which just sucked) and only after deciding to separate one of the vacuum lines from the bunch of three heading back there. Apparently someone thought to be frugal by splicing a one inch section of hard vacuum line instead of providing one line of an adequate length for the application.

I started it up to see if I was back to square one and was it idling rough but I have yet to drive it. We'll see shortly...

I would like to purchase and replace all of the potential vacuum elements and fuel filters lines etc...before moving into the glow plug elements but I'm sort of lost in all the information I've been reading.

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1991 300SL 71K miles young

Unfortunately, I'm not back at square one...pretty good bang on shift from 2-3. It did diminish a bit with warming up on the drive to work about 3 miles but the shifting is horrible.

I really need to get in under that resonance switchover/crossover manifold asap to clean up that vacuum mess...

Is there is no way to remove just the resonance intake manifold by itself?

I don't know how else to help myself with this issue...are there search terms I should be using?

Help!

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1991 300SL 71K miles young

When I took mine off, I first took the EGR vavle body with the throttle valve in it off completely. You'll need to disconnect the link rod which comes across the top of the engine to the thottle valve. This frees up one end of the resonance crossover manifold - there's a large O ring between it and the EGR valve, so it'll need a bit of a wiggle to free it.

Then, there's just the allen bolt at the other end.

At this point, the manifold should begin to feel a bit more free. Give it a wiggle, and you will be able to free it from the O rings at the IP side of the engine (I think driver's side for you). Now, the only things left connected to the crossover manifold should be the vac pipe itself.

Thank you!
I've attached an image of my 606 for reference - so you are saying that I cannot detach the crossover manifold portion that connects to the intake line from the portion (circled in blue) that connects to the EGR and throttle valve?

Below is the alldatadiy instructions (diagram attached) for removing the crossover manifold that led me to believe you can separate the portions of the crosssover manifold. If the O rings look good can I just reseal or do I need the "hot lubricating paste" (and new O rings) if I'm just pulling it to get to the vacuum elements?

Removing and Installing resonance intake line

Engine 606.910

Unscrew bolt (99/6) at resonance intake manifold.
Unscrew bolts (99/7) at bracket of resonance intake line (99/1).
Detach vacuum line (99/8) of vacuum unit of resonance intake flap.
To do this, raise resonance intake line.

Remove resonance intake line (991).
Examine 0-rings at intermediate piece of vacuum control flap housing/resonance intake line and resonance intake line/resonance intake manifold, replace if necessary.

Installation note Insert 0-rings with hot lubricating paste, part no. 000 989 76 51.

Attached Thumbnails

   

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1991 300SL 71K miles young

Using "e300d egr" I just found a thread with "diesel crossover pipe" in the title. From what I can gather apparently the part I circled in blue is a component of the EGR? I checked alldatadiy for identifying information and it just runs me in circles giving me repair times for anything associated with EGR. @#%$$@#

Looking at Lightmans killer Glow post I can't tell...doesn't look like there is the same crossover manifold.

I have scoured here google, alldatadiy, my books and autoparts sites for a reference image of engine (and at least the intake manifold system/related elements) with names so that I can understand what I'm reading.

Does this exist? Will it be provided on the CD I ordered from MB...or will I use it as a coaster for my coffee, the books for kindling a fire and shave my head with a cheese grater while chewing on tin foil? Anyone else there?

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1991 300SL 71K miles young

I have a '96 with the same engine. It helped me to loosen and remove the bracket near 99/7 from the head just for more wiggle room. As far as the hot paste, the parts guy at the dealer could only get the stuff in large quantities and said it was probably just high-temperature grease so that you can put it back together more easily without damaging or dislodging the O-rings. I used CRC brand synthetic brake and caliper grease (high-temp and not harmful to the O-rings).

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Byron Herrington
'96 E300D 162,000 miles
'97 Toyota Land Cruiser
'92 400E (sold)

Also, the part circled in blue is the vacuum actuator and linkage to intake pressure control flap, which I gather works in tandem with the EGR control system.

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Byron Herrington
'96 E300D 162,000 miles
'97 Toyota Land Cruiser
'92 400E (sold)

Thanks Byron!

I had the bracket rotated and swinging freely from the bottom bolt on the head and I still couldn't budge the crossover manifold. Do I need to wrap a sturdy wrench in an old towel and gently pry it away from a particular point of reference?

So, to be clear, there is a seam between the portion of the manifold that crosses over and the part that is circled in blue which is the control flap housing. In looking at the diagram again I noted the reference to the "vacuum control flap housing/resonance intake line". Duh!

Should the crossover portion separate from it without too much trouble?

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1991 300SL 71K miles young

Yes, when I took mine apart, I took the whole of the EGR / vacuum flap unit - the bit you circled in blue- off, because I was going to carry on and take the cylinder head off.

I don't know if you can get the manifold off without completey removing the EGR unit, because I've never done that.

Between the manifold and the EGR unit, there's a big O ring, and you just need to wiggle the parts relative to each other to get them to part. Yes, it was quite tight. I used some rubber grease - of the type recommended for brake seals to lube the O ring when I put it back together.

I tried to navigate this site once after seeing someone post some incredible schematic...for whatever reason it looked like a blank page and I didn't see a scroll bar for more below.

Wow! This rules...posting so that someone else looking for this stuff may find it. Click on the link (INTAKE AND EXHAUST...) and scroll down to your amazement for the original link with parts associated with this and every other schematic it seems.

Модель / Системы / Узел: 14 INTAKE AND EXHAUST MANIFOLDS
Модель=606910 Каталог=19T Система: 14 INTAKE AND EXHAUST MANIFOLDS
Иллюстрация: 030 Узел: INTAKE MANIFOLD

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1991 300SL 71K miles young