I've acquired a 606 non turbo as a donor engine to replace my dying 603. I'm just in the process of replacing 2 glow plugs which fortunately came out no problem.

To do this I took the inlet manifold off and found some electrical connections to various valves etc where the insulation had crumbled away (a common problem I think) so I've repaired those with heat shrink and re soldered some.

Anyway in doing so I can see a load of vacuum lines doing who knows what, some obviously for the auto box others seem to be operating buterfly valves in the air intake.

As I will be using a manual gearbox, chucking the egr valve away and probably not using the electronic idle control my question is can I do away with all these vacuum lines? If not all what can I do away with?

I'm going for simple reliability and don't want any weak areas.

Thanks.

The butterfly valves in the intake manifold and crossover pipe "tune" the intake and increase torque. The engine will run even if they don't work but the torque curve will be affected. The electronics that operates them is the same as operates the electronic idle control.

Jeremy

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"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

OK thanks for the reply I guessed it maybe, so I really need to try and preserve these functions when I do the swap.

Would anyone have a schematic of the vacuum lines and the wiring please?

Thanks.

__________________

"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

Brilliant just what I needed, thanks very much.

Recommend taking apart those butterfly valves and give them a good cleaning so they operate smoothly.

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1995 E300 diesel

a bit of a clarity here - because I ripped about 3 handfuls of hair while repairing my car for a dodgy idle.

the idle control is done solely by the ELR which takes reading from the tach and thermistor on the engine cylinder head.

The manifold flappers are driven by the EGR control module, it also takes reading from the tach sensor and thermistor and also the rack position.

Mine used to get stuck in "working state" - the fault was the similar wiring fault like the idle system - and the odd bit was the wiring was in beautiful shape - genuine MB replacement part of 2007 build - still it had 3 brown wires misrouted.

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2012 BMW X5 (Beef + Granite suspension model)

1995 E300D - The original humming machine (consumed by Flood 2017)
2000 E320 - The evolution (consumed by flood 2017)

so if the EGR is disabled the manifold flappers don't work? Should they be set in any particular position in this case?

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1995 E300 diesel

The flappers will keep working unless you actually pull out the EGR control cube from the car. Disabling the EGR in this car is pretty basic oldschool, stick a BB in the vacuum line, remove the mid linkage from the accelerator and tie the flap wide open.

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2012 BMW X5 (Beef + Granite suspension model)

1995 E300D - The original humming machine (consumed by Flood 2017)
2000 E320 - The evolution (consumed by flood 2017)

@ Jeremy,

sorry to have sounded a bit rude - but as support for this car is already scarce I thought I would add my 2 dollars experience with resolving this issue.

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2012 BMW X5 (Beef + Granite suspension model)

1995 E300D - The original humming machine (consumed by Flood 2017)
2000 E320 - The evolution (consumed by flood 2017)

thank you for that!

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1995 E300 diesel