thanks i'll do that

Red:

Did the engine come with an injection pump installed, or did you install the old one yourself?

Have you tried disconnecting the EGR valve actuating vac line? A stuck EGR will cause all sorts of problems, but that big cloud of inky black heavy smoke is a classic, especially if at low speed and you floor it.

How much did you get with the engine? Was it complete with head and manifolds, or did you only get a long block, had used the old head, manifolds, injection pump, starter, etc?

Something is definitely wrong here, it should run like new.

Peter

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1972 220D ?? miles
1988 300E 200,012
1987 300D Turbo killed 9/25/07, 275,000 miles
1985 Volvo 740 GLE Turobodiesel 218,000
1972 280 SE 4.5 165, 000 - It runs!

engine came with everything except AC compressor, cruise control module, and the alternator, and maybe the powersteering pump. pretty much as complete as it could get.

also the EGR system is brand new about 2000 miles ago. engine has 20G on it. and in 2000 miles that EGR system should not be stuck, unless there is something wring in the engine. oil going through the EGR system? we have no idea. thanks

Red:

Have you put in new fuel filters and checked for leaks in the fuel system? There is an o-ring where the fuel suction line enters the lift pump (lower left side of IP). If this is leaking, and you have air entering the fuel system, all sorts of strange things can happen.

I have had loose pressure valve holders on a 603 pump, but I'd have MB check that, it's still under warrenty. Causes serious "nailing" (injector knock), hard shake (rattles your teeth), but runs fine above 2000 rpm. Hard to diagnose, too.

You can check the egr by pulling a good vac on it with a hand pump (or by mouth if you are brave) and let is snap closed. If it sticks open, there is the problem. YOu can also just pull and plug the hose, see if the smoke is still there.
Peter

__________________
1972 220D ?? miles
1988 300E 200,012
1987 300D Turbo killed 9/25/07, 275,000 miles
1985 Volvo 740 GLE Turobodiesel 218,000
1972 280 SE 4.5 165, 000 - It runs!

i will mention this to my dad before he goes into the dealership. the loose pressure valve holders could be the culprit. although when we get new injectors the miss goes away, and then comes back in about 2 weeks.

maybe it is the EGR, but like i said it is all new 2000 miles ago. why would it be screwed up already? maybe faulty parts. this is getting frustrating. we want this engine fixed before the warranty goes up. thanks

Mine has a factory re-built 300 5cyl turbo (617 engine). It's got about 30,000 miles on it, and it uses MAYBE 1/2 quart of oil between oil changes (3,000 miles). And I think most of that is from the leaking seal at the turbo-oil return line. I can't believe Mercedes would consider 1000 miles/quart as acceptable. (Are those 603 engines really that bad?)
Mine has a metalic clank when it's cold too. Sounds like only one cylinder is doing it. I've heard others refer to this as "nailing", although I haven't heard exactly what it is, what causes it, or how to get rid of it.

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past MB rides:
'68 220D
'68 220D(another one)
'67 230
'84 SD
Current rides:
'06 Lexus RX330
'93 Ford F-250
'96 Corvette
'99 Polaris 700 RMK sled
2011 Polaris Assault
'86 Yamaha TT350(good 'ol thumper)

the metallic clank is hard to explain. lets put it this way...it is so loud, that you if you are standing infront of the car, you have to yell at the person next to you so that they can hear what you are saying. the old engine did not do this. the only sound that the old engine would make when cold is at bout 900 RPM or so, the engine would clank a little, and when it got warm it wouldn't do that. thanks for all the help so far.