EGR valve removal & block-off photos - PeachParts Mercedes-Benz Forum

gsxr · #1 12-30-2002, 11:23 AM

Hi all,

I think I forgot to post this. (?) I removed the EGR valve from my 1987 300D recently, as it was leaking oil from the EGR body itself (intake pressure going past the internal valve stem seal). I had it disabled for years but finally yanked it off totally. The intake is the easy part, you just need a blank plate of 1/4 inch steel or something. The exhaust was more of a pain. I cut a 42mm (?) circle of sheet metal and then snipped little "V" cuts around the edge every 2-3mm or so. Then I hammered it into shape over the exhaust manifold port, applied red RTV to the sealing faces, and put the stock clamp back on. So far it's been working great, no leaks! And I'm happy about having that ugly, leaking hunk o' iron off my engine! This will work on all OM60x engines as well as OM617 engines, since they use the same size EGR openings for both the intake and exhuast. Here's the photo:

P.E.Haiges · #2 12-30-2002, 12:03 PM

I wouldn't publish tampering with air polution equipment. The EPA Gestapo is liable to show up and knock down your door.

P E H

gsxr · #3 12-30-2002, 12:11 PM

Oh yeah, I forgot to mention, this is on a race-only engine, for off-road use... no EPA regs there!

P.E.Haiges · #4 12-30-2002, 01:18 PM

Gsxr,

Tell it to the Judge. LOL

P E H

P.S. Nice job.

#5 12-30-2002, 02:32 PM

Dave, did you ever figure out that odd oil leak you had around your exhaust manifold?

gsxr · #6 12-30-2002, 03:40 PM

XN6,

If you're referring to the oil leaking from the #6 exhaust port with my NEW cylinder head back in February, well, sort of. I narrowed it down to valve guides or seals. But I haven't checked further. I plan to pull the camshaft and visually inspect the seals, to see if they are present, and if installed properly (not backwards- intake & exhaust are different.) If that all looks OK, then the head will have to come back off (ugh!) and go to a competent machine shop for further diagnosis. The weird part is, the shop that did the work has a very good reputation and they do a LOT (probably more than 1/2 or 2/3) of the Mercedes head work in the Sacramento area. So if they didn't goof, then it's possible the valve guides in the new head were bad... either way, it's REALLY annoying to have a silly leak like that after spending ~$3k for a new head!!!

Otherwise the car runs great and got 32mpg on several tanks this spring - wow! The calibrated I/P probably helped too.

UPDATE: The weird oil leak was a dislocated exhaust valve seal. I replaced all the seals with OE dealer seals, which are a compeltely different design than the aftermarket seals I had before. It's all detailed in my "OM603 oil leak" thread, which you can find with the Search feature...

Regards,