Last night I swapped the vacuum hoses to the flaps. I had to put in new hoses because the originals were not long enough to be crossed. It seems wrong to cross them like this, but at least now my flaps open in the correct sequence. I didn't feel any noticeable difference while driving the car this morning, except I didn't hear the highway ping that I would sometimes hear before. Maybe it's proper now.

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2004 VW Jetta TDI (manual)

Past MB's: '96 E300D, '83 240D, '82 300D, '87 300D, '87 420SEL

>>Number_Cruncher, you should really take your car out and thrash it occasionally. The 606 engine is made to spin up to 5400 RPM.

Yes, I do tend to "baby" it a bit, but, with fuel at over £1.20 a litre, I try and be as light-footed as I can!

>>Your LED monitor is clever, I may shamelessly steal the idea.

It cost pennies to make - standard LEDs, and a 330R resistor in series, and some thin speaker wire. I put it together because I wasn't sure how the flaps should actually work. There's some MB info, helpfully posted by Grober in this thread;

http://www.mbclub.co.uk/forums/showthread.php?t=49287&highlight=3%2F6

Can anyone post photos of this LED arrangement?

>>Can anyone post photos of this LED arrangement?

No, sorry, it was a temporary fitting, just to enable me to see that they worked, and at what engine speeds they switched. The bits have long since been taken off the car, and disposed of.

I didn't see any difference between revving the engine, and the behaviour while driving (as I understand it, that particular ECU wouldn't have a vehicle speed sensor input anyway). I'm not sure if that's also true for the more complex control that's fitted to W210s.

There was really nothing to it, just some cheap wire, some resistors, and some LEDs. As it was temporary, I used some cardboard with holes in for the LEDs, and I wrote by each LED what it was monitoring.

Update. So far so good after the vacuum hose swap. Car may be a little stronger now, but hard to say for sure. The highway ping has not returned yet. Just out of curiosity if anyone has the crossover pipe off can you check your vacuum hoses going to the flap controller? Like I said I had to cross mine to get the flap opening sequence right.

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2004 VW Jetta TDI (manual)

Past MB's: '96 E300D, '83 240D, '82 300D, '87 300D, '87 420SEL

Here's a link to an MB test procedure for the flaps...

http://www.w124performance.com/service/w124CD1/Program/Engine/605_606/14-7550.pdf

Just checking the operation of mine.

Is there a possibility that the valve located within the crossover pipe only opens above 3k rpm when warm?

I need to double check this but at first glance mine doesn't work when cold.

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David


1996 Mercedes S124 E300TD - 129k - rolling restoration project -

1998 Mercedes W210 300TD - 118k (assimilated into above vehicle)