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Old 05-12-2010, 07:53 PM
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Join Date: May 2010
Posts: 24
Testing Vacuum Control Flap on 1992 300D

I have been troubleshooting issues with loss of boost on my 1992 300D. After a few minutes of driving the boost turns off and restarting the car clears up the issues but only temporarily. The EGR valve was 100% restricted but there was no change after cleaning everything up.

In trying to set the Vacuum Control Flap i am running into some issues. Can anyone tell me the correct behavior of the vacuum unit on the control flap (part 100 in diagram) and MB part number 603 090 10 66

I assume it is most likely bad since i am barely able to pull more than 5 hg in on the mityvac when it looks like it should be set at 11 hg in. Or am i way off in trying to get this set?

I have not been able to find much information about this. Should it slowly leak vacuum? I can not get the valve to fully close with the mity vac, is this normal?

Thanks in advance for any advice, opinions or entertaining insults.


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Old 05-12-2010, 11:20 PM
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Join Date: May 2010
Posts: 24
The part i am having problems with is #47 on this diagram.

If this does check out as bad anyone have any ideas on where to source one beside the local MB dealer? I am having trouble tracking down the part number anywhere.
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Old 05-13-2010, 04:07 AM
compress ignite's Avatar
Drone aspiring to Serfdom
Join Date: Feb 2004
Location: 32(degrees) North by 81(degrees) West
Posts: 5,554
An Upgrade to Fix ALL Your EGR/Flapper Distress

Settle down a couple of nights this week and read ALL of gsxr's post on Emancipation from EDS
(Electronic Diesel System[A.K.A. "The Computer"] ) Enslavement.
ANY action by the Electro/Vacuum Actuator/Sensor/Flap System EXCEPT
the factory setup causes the sensors to "Tattle" to the EDS which then
cuts ALL your Boost.The Ignition "Cycle" you are going through with the
key RESETS the EDS control of your BOOST Momentarily/Temporarily.

AND Yes the Poor Little EDS will be setting codes,BUT that's ALL it can do.

Wastegate actuator swap for OM602.962?

Synopsis: you replace the Vacuum Operated Turbocharger Wastegate with
a Pressure Operated one...AND throw All that Rat's Nest of Electro/Vacuum
Actuator/Sensors/Flaps in the ReCycle bin.(Or sell on Flea Bay)

In the Left hand Pictogram the Turbocharger (#5) IS a Pressure operated one
,Just like you're gonna switch to!

The ONLY Function of #47 is to CHOKE OFF the CLEAN AIR Intake @ Idle/Low RPMs
'84 300SD sold

Last edited by compress ignite; 05-13-2010 at 04:21 AM.
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Old 05-18-2010, 01:05 PM
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Join Date: May 2010
Posts: 24
Thanks for the suggestion, the parts from ATP are supposed to be delivered this week.

Just trying to decide where the tap should go, on the turbo housing or somewhere that does not require removing the turbo. Hopefully i'll have boost back full-time after installing everything this weekend.
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Old 05-18-2010, 01:43 PM
92 300D 2.5L OBK #59
Join Date: Feb 2007
Location: Central FL
Posts: 1,108
Are you doing the pressure activated mod??? I've posted pictures how I took pressure from the manifold where it feeds the alda. Insert a "T" Fitting then run the hose back to the actuator.

If you check out the pictures you can see how I ran the pressure hose.
Wastegate actuator swap for OM602.962?
92 300D 2.5L OM602 OBK #59
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