Free EGR delete kit
 

Remove the two bolts on your EGR valve and slip out the metal gasket (this will be your template) then get a piece of sheet metal and trace the gasket including the two mounting holes. take a tin snips and cut out the new gasket and drill the two mounting holes as well. slip this new gasket in place and bolt it back together.

For more flavor:

https://www.dieselbombers.com/attach...d-617-egr1.jpg

-Rog

I made mine out of an old soda can....

I've seen reference to disabling with a BB in the vac line. Keep your pieces in case you have to reinstall to pass the changing emissions requirements.

I highly doubt any inspector would be framiliar enough with an om617 to know the egr was missing or disabled.

I put a piece of pop can between the edge valve and the manifold so that you couldn't tell it was blocked off, also it meant that I didn't have to make a plate.

I used a PBR can on my 300TD, and it passed inspection. I would definitely put a little bit of this on there, mine started leaking exhaust gases and I resealed it with this and it has been find ever since.
http://triumphbonneville.org/uploads...st-sealant.jpg

My VW TDI I had a full delete on it, including removal of the EGR Cooler, and they didn't catch it!

I turned around the check valve on the line so that it wouldn't get vacuum.

I bought the delete kit from Rollguy here for ~$15. Well-made w/ chromate coating on the intake plate. That lets you remove the EGR valve completely, which makes loosening the alternator easier (still not trivial). I also removed all the EGR vacuum controls (per thread here). I expect if it isn't working correctly, the EGR system makes the engine pollute more, and hard to assure it is working right. No emissions inspections on these old diesels in CA.

Literally all it takes.

Stick a BB in the line, reinstall line for stock look - no need to futz around with anything else, just effective. These delete kits are more of a "look" thing in reality.

Isn't the potential concern the possibility that the valve could be stuck open? That the blocking plate is the only way to guarantee absolutely that exhaust gas won't enter the intake?

Absolutely, but its not like it's the most difficult thing to clean out should that be the case. Once it's closed and there's no vacuum to open it, there's no chance for it to open obviously.

I'm constantly getting cars in that have had EGR deletes where the vacuum system is improperly removed, or left uncapped. While it ultimately doesn't matter to early cars - the later vacuum wastegate cars are left nearly boostless.

I've just found the BB in the line and leave it be is a relatively costless, extremely reversible endeavor. :)


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Not MB motors but with GM 6.2 diesels 'light duty' motors, just install manifold gaskets for heavy duty 6.2's to block the 'crossover', blocking exhaust gas from intake.

Just an aside on guilt of polluting more. My 2 Chrysler minivans (2.4L & 3.8L) have no EGR. There are block-off plates for it, since the same engines used in "passenger cars" do have EGR. Why? Because minivans are "trucks" so can pollute more. In the 1970's, Congress feared impacting businesses w/ pollution laws and every voter fears losing their job. If you really want to pollute, buy a massive F350 "commercial truck" and drive around like a true false patriot wasting petroleum, with a big 'merican flag in the back.

I suppose there are several methods for blocking the EGR (and we are all going to hell for doing so) but the thin metal plate seemed the easiest to me. I see some people removing the flex pipe from the exhaust manifold to the EGR valve and sealing that off as well. It doesn't have to be so complicated.

Does the BB trick work on a 2012 e350 with the OM642? Sorry if this is a noob question, but I am just now getting into fixing my car as it is off warranty and starting to act up.