Recently I completed the vacuum wastegate actuator swap and made my own egr block off plates. the one on the manifold is made of copper, and on the charge pipe is 16 gauge steel. I drilled and tapped the charge pipe block plate and installed a fitting to feed the pressure actuator via a rubber hose.

my question is, how can I remove the intake flapper thing on the other side of the charge pipe from the egr? I would be ok with just removing the guts of it and leaving the outside stuff there if possible.

__________________
'92 300D 2.5
'99 E300TD

That's what I did on my '95 E300D, a somewhat different engine with the same kind of intake throttle. You should be able to remove two Phillips screws holding the flap to the rod, pull out the flap, and leave everything else in place.

Jeremy

__________________

"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

Awesome pics, and thanks. I guess its like a throttle plate on a gas engine. The inside of yours looks WAY cleaner than mine.

__________________
'92 300D 2.5
'99 E300TD

Yes, it's very much a throttle, designed to lower the pressure in the intake manifold so more exhaust gas is sucked into the engine. Once EGR is disabled, you can clean up the intake and it will stay clean like mine. Later engines (1996 on) have a pressure sensor; the throttle plate cannot be removed or a code will be set, alas.

__________________

"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