Just installed RollGuy’s EGR delete kit. His is basically the identical to all of the others, using the original exhaust clamp to affix a “cap” where the EGR valve would usually sit on the header. The cap is certainly centered, clamp tight. I even sprayed the cap with some copper gasket to aid in sealing. Still leaks a little. Can’t hear a massive leak, but it bubbles big time with soapy water.

Any ideas??? I’d like to avoid removing the header again and welding it shut.

Perhaps slap some of exhaust sealing goop on the cap and try again? As this is a header, I’m sure it sees more heat and pressure than stuff downstream where that hoop is traditionally used

It's not pretty but rtv can seal it.

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I cut a circle out of an old licence plate tag and put the original clamp on it. No leaks.

Oh, I did cut a short piece of the original tube as the flare is needed for the clamp to hold.

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Pic

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I'm working on my 78 Datsun Z and had an interesting discussion regarding finding engine vacuum leaks. Even though diesels don't have vacuum, this might help someone.

Harbor Freight sells this fluid transfer pump. https://www.harborfreight.com/multi-use-transfer-pump-63144.html

Connect the inlet to a cigarette. Connect the other end to a port going into the engine. I used the brake booster on the Z but there is probably some access to the 6xx MBZ engine.

Anyway, pump the smoke into the engine. If it escapes, you've found your leak and can direct your attention to gaskets or whatever.

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85SD 240K & stopped counting painted, putting bac together. 84SD 180,000. sold to a neighbor and member here but I forget his handle. The 84 is much improved from when I had it. 85TD beginning to repair to DD status. Lots of stuff to do.

Sounds like this is a prob thats been around for a while.

I’m going to dump some sealing goo in there to start with. If that doesn’t work I’ll do Inshans method, which is pretty smart because it re-uses the flange of the original EGR pipe which the header and clamp require. I suspect the “cap” is either too small, thus easily off center, or its curvature doesn’t match the EGR flange close enough

And if all else fails, I’ll get off my arse and machine a beefier cap that matches the EGR pipe flange