OM606 non-turbo EGR mod link
 

I performed this mod this past weekend and made a quick tutorial..

ENJOY!!!!!!

Forgot to add the link..

Select the EGR link from my main page

I replaced my injector return hoses today and found all that cr*p in the crossover pipe (95/606.910) that the egr allows in the system. I would have thought that the 'brain box' would have noticed dif input and caused a problem? So I'm assuming everything runs in a normal fashion- what benefits have you noticed. I believe the only dif twixt our motors is your later computer and diagnostic ability.

Nice Job! Two questions:
1. Does the om606 non-turbo use the same "long" gloplugs the 98-99 Turbodiesels use? Are they prone to breaking on removal like the 98-99's?
2. I take it the reason you attach a small filter to the EGR inlet instead of plugging it is so it can continue to function without it knowing it is only flowing clean air and not exhaust? Is that why it doesn't trigger a CEL? If so couldn't you attach a length of black 3/4" heater hose to the EGR inlet and route the hose to the post-filter section of the airbox/filter housing? I only mention this as the little filter definitely looks "aftermarket" where another black hose running to the airbox may look much less innocuous and more stock to the untrained eye?
Just a thought.
RT

Ok, here is what I've seen so far. I saw in an earlier post that 97E300D performed this exact mod and revieved no CEL lights. So, this weekend I got the time to do it. But for the past two weeks I've developed a hesitation problem that usually appeared right before I shifted into second or after, and rarely into third. After I had performed this mod this all went away. Why , how beats me.

After consulting the w210 tech manual I read the quick section they have about the EGR. All the electronic sensor on the top of the EGR does is to measure the quanity of air passed. So, taking this into consideration and that fact that 97E300D performed the mod with no probls, it was a go.

Aside from my coincidental dissapearance of my hesitation problem, after performing this mod I have noticed the engine runs a lot smoother AND, the engine warms up faster, about half the time previously. Perfect mod for "chipping" the engine at a later date since it adds more fuel to this "now" oxygen rich environment.

1. I would assume the 96-97 use the same glowplugs since it's an OM606. But then again you brought up a good point. I would assume the glowplugs are the same throughout all the years of the OM606.

2. The reason I attached a small filter to the EGR inlet is to allow it to function like it did previously, but with fresh air. No CEL's are triggered, because it is measuring the amount of gases passed, not what kind it is.

You can make the EGR filter setup look how ever you want, makes no difference, I took this method such that if I needed to switch back I could. Eventually I will change this ventilation setup yet again to make it a more OEM look.

It's funny you mentioned that airbox method, I was contemplating trying a setup like that next so that I wouldn't have to worry about "extra" filters to replace, and honestly it was hard to find one that worked as well as this, because this is the only breather element in the auto parts stores.

To anyone with an OM606, if you're a DIY'er, DO THIS MOD! You're engine will thank you as soon as you turn it on :D

Here is a picture of the EGR valve...

http://www.michakaveli.com/egrmod/egr.jpg

Why not just disconnect the vacuum line to the EGR and plug it with a golf tee?

That won't work because the computer is monitoring the airflow. Simply blocking or disabling the EGR will set the Check Engine light.

Gotcha. The 95 e300d doesn't have one those.

Chuck, I think he was refering to the guys with the later models that have the dif computer and on board light system (606.912). Same basic motor but upgraded (more complex) monitoring system.

Mich, I posted your basic info on the tech page to get the 'tech guys' take on the mod. Looks like a good mod to me.

EGR bypas
 

Hi might be a silly question but why did Mercedes not pipe it from the clean air side of the filter???

Peter

Re: EGR bypas
 

Just think about all that gunk in the intake manifold enging up in the air filter. Then think about all the gunk that went into the cylinders without getting stuck to the manifold walls. :eek:

You would likely waste an airfilter in a week or so...

The point of the whole thing is to get exhaust gases, not fresh air, into the intake tract. The oxygen-poor environment reduces oxides of Nitrogen emissions at part throttle.

Blocking or disabling the EGR has been tried unsuccessfully on 350SDL/S350 and on 300D 2.5 Turbo. I think as early as 1992, maybe 1991, the computer was smart enough to cut the boost if the EGR was disabled. Having no turbo, you don't have to worry about that. So if you don't have a check engine light, then you might be good to go. Of course you realize it is illegal. :rolleyes: