Trying to be proactive in maintenance.....have had several episodes in last few months of "engine...hesitating at part load with no fault codes." Car would not downshift and turbo seemed inoperative. All restored to normal after car shut off and restarted. Dealer said to wait till it starts to throw codes (if ever).

Any first hand experience on EGR clogging? The first 2005 CDIs had a different EGR valve that was replaced by MB along with software upgrade. I wonder how many of the first type of EGR valves caused/will cause problems? Wonder how many of the new EGR valves will cause problems?

How many of the 2005s had work done by MB (please check your VMIs and report back)?

Here is excerpt from DR. Diesel in 2006:
----------------
Quote:
Originally Posted by DR.DIESEL View Post
Hello,

Those EGR valves have been known to be trouble and were modified.

See the following Dealer technical Bulletin.

DTB Date: January 10, 2006
Order No.: P-B-07.16/55a
Supersedes: P-B-07.16/55 dated October 31, 2005
Group: 07
SUBJECT:
Model 211.026
Engine Performance Complaints / Check Engine Light On with Code 2511 and/or 2355
If you receive customer reports in the above model vehicles of the engine being in limp home mode with the check engine light illuminated with fault code 2511 and/or 2355 stored in the engine control unit (ECU) or
the engine is surging/hesitating/misfiring at part load with no fault codes, perform the below procedure to resolve. These may be caused by the EGR valve temporarily binding and consequently exceeding the setpoint and causing the fault code and limp mode condition; or the software version in the engine ECU (lean condition under certain RPM/load, temperature and fuel quality conditions).

To resolve, install modified EGR valve (see parts information) combined with ECU software update (available as patch 2005-10-13-0474 with DAS update 10/05 and later DAS updates without patch).
Note: It is important that the modified EGR valve is installed together with the modified engine ECU software and vise versa.

Note: After the software flash, perform SCN coding (refer to Star Tekinfo Document S-B-07.61/38g or S-B-07.00/144) and verify injector coding.

Parts Information
Qty. 1 EGR valve A646 140 19 60

I would ask your Dealer about some goodwill reimbursement or checking the Fedral 8/80 emmissions warranty for that model.
If no luck, call the CAC at 1-800-FOR-MERC and start squeaking.
The regional SPOM will be notified of your complaint and should respond.

Good luck.
DR.D
--------------------

Any shared experiences would be helpful to me and future members......

__________________
-- Chris

'95 E300, 216k miles, Silver Surfer
'05 E320 CDI, 138k miles
'07 S550 4matic, 69k miles

Gone but not forgotten:

'76 300D, 350k miles?, SOLD in 1995
'75 240D, 300k miles, SOLD in 1991

Does the car use a DPF system - it could be clogged causing issues perhaps? This is why I always ensure that the EGR system is disabled on any of the diesel cars I own, its ok on a petrol but not on a diesel as the exhaust clogs up all of the nice clean inlet.

__________________
UK spec Mercedes W210 E300 Turbodiesel wagon - OM606.962 with 722.6 transmission - rust free!

Unfortunately our government over here does not see it that way.

__________________
The OM 642/722.9 powered family
Still going strong
2014 ML350 Bluetec (wife's DD)
2013 E350 Bluetec (my DD)

both my kids cars went to junkyard in 2023
2008 ML320 CDI (Older son’s DD) fatal transmission failure, water soaked/fried rear SAM, numerous other issues, just too far gone to save (165k miles)
2008 E320 Bluetec (Younger son's DD) injector failed open and diluted oil with diesel, spun main bearings (240k miles)

1998 E300DT sold to TimFreeh
1987 300TD sold to vstech

My understanding in modern vehicles the egr is used only the first few minutes of starting the engine.I have read several articles that they are the slow death of diesel engines.VW forums say to save your engine,rid the motor of that device.Its like trying to make a marathon runner breathe carbon dioxide.

__________________
1999 w140, quit voting to old, and to old to fight, a god damned veteran

No DPF on 2005 & 2006 CDIs in US that use OM648 engine. MB seems to have changed the EGR valve during the 2005 model year production of the these vehicles. Tech bulletin refers to replacing it and reflashing ECU if owner has issues with power loss or certain codes.

__________________
-- Chris

'95 E300, 216k miles, Silver Surfer
'05 E320 CDI, 138k miles
'07 S550 4matic, 69k miles

Gone but not forgotten:

'76 300D, 350k miles?, SOLD in 1995
'75 240D, 300k miles, SOLD in 1991

I believe you're confusing EGR with Air Injection, which is used on gasoline engines to heat the catalytic converters up quickly. EGR is pretty much active, although variable, at all times except at idle.

I bought my 2005 cdi in Feb/March of 2005. On a long trip I started the limp home mode, no kick down. It would be fine after a restart. I had about 8000 mi on the vehicle. It took 3 dealers to figure it out. they replaced the EGR valve under warranty. I now have 243,000 and it runs great. I checked the valve maybe 100,000 miles ago. ( I have my records but I'm on my laptop in Vail and my desktop has all my records). When I checked it, it was clean. I put a new gasket on it and haven't touched it since. I have the exact mileage for the replacement and cleaning at home. Steve

08/17/06 48667 EGR valve
03/16/11 123069 service EGR swirl motor & flaps
04/01/13 163618 engine control unit, EGR valve
04/17/13 163618 swirl motor
05/03/13 164403 EGR cooler gasket, intake manifold gasket

__________________
Greg
2012 S350 BlueTEC 4Matic
2007 ML 320 CDI
2007 Leisure Travel Serenity
2006 Sprinter 432k
2005 E320 CDI
1998 SLK230 (teal)
1998 SLK230 (silver)
1996 E300D 99k, 30k on WVO
Previous:
1983 240D, on WVO
1982 300D, on WVO
1983 300CD, on WVO
1986 300SDL 237k, 25k on WVO (Deerslayer)
1991 350SDL 249k, 56k on WVO - Retired to a car spa in Phoenix
1983 380 SEC w/603 diesel, 8k on WVO
1996 E300D 351k, 177k on WVO

Thanks for the info. I suspect that MB did not notify early owners of the issue with the EGR that was installed on early 2005 models here in US. They only fixed the problem as a warranty issue if an owner complained.

Replacement EGRs seem to have fewer problems.

__________________
-- Chris

'95 E300, 216k miles, Silver Surfer
'05 E320 CDI, 138k miles
'07 S550 4matic, 69k miles

Gone but not forgotten:

'76 300D, 350k miles?, SOLD in 1995
'75 240D, 300k miles, SOLD in 1991

Is your 2005 early production? Was the listed work done while you owned the vehicle?

__________________
-- Chris

'95 E300, 216k miles, Silver Surfer
'05 E320 CDI, 138k miles
'07 S550 4matic, 69k miles

Gone but not forgotten:

'76 300D, 350k miles?, SOLD in 1995
'75 240D, 300k miles, SOLD in 1991

Early. First service work was replacement of the Command head unit 10/05/04 @ 2652 miles.

I bought the car this Feb. w/196k.

__________________
Greg
2012 S350 BlueTEC 4Matic
2007 ML 320 CDI
2007 Leisure Travel Serenity
2006 Sprinter 432k
2005 E320 CDI
1998 SLK230 (teal)
1998 SLK230 (silver)
1996 E300D 99k, 30k on WVO
Previous:
1983 240D, on WVO
1982 300D, on WVO
1983 300CD, on WVO
1986 300SDL 237k, 25k on WVO (Deerslayer)
1991 350SDL 249k, 56k on WVO - Retired to a car spa in Phoenix
1983 380 SEC w/603 diesel, 8k on WVO
1996 E300D 351k, 177k on WVO

Many "tunes" like that from Green Diesel disable the EGR 100% of the time; it'll never malfunction.