OM606.910 EGR Delete (No extra filter req'd)

[jwilson76239]

The OM606.910 in the '95 E300 Diesel can have its EGR removed the "old school" way. No extra air filter required: just delete it. The '95 does NOT have a check engine light, nor does it have any kind of sensor which could verify proper functioning of the EGR. One could suppose that the EGR control module could sense current flowing through the electronically operated vacuum valves, but I deleted them as well and experienced no (apparent) ill effects. I also deleted the vacuum amplifier. My vacuum system now corresponds to the diagram in the FSM labeled as "Automatic w/o Kat," which I take to be the Euro configuration for the automatic. Despite deleting my EGR, I ended up replacing my dead EGR control module because it controls (via vacuum valves) the flaps in the crossover pipe and the resonance manifold. Here are some pics:






The "extension piece" for the crossover pipe was made from aluminum stock ordered from McMaster-Carr (approx. $50). The female end of the crossover pipe was slightly bored out to make it smooth and the O.D. of one end of the extension piece was machined so that it fits very tightly into the crossover pipe (lubrication, a rubber mallet, and patience were required to mate the two). The mid-section of the extension piece was machined to have an O.D. such that it would be flush with the crossover pipe when fully inserted. The other end had the O.D. machined to equal the I.D. of the ridged rubber piece leading to the filter box.
All electronic connectors which connected to the vacuum valves associated with the EGR (which I deleted) were simply disconnected and tucked behind the air filter box.

The EGR port on the exhaust manifold was blocked using aluminum sheet metal cut with tin snips and Permatex® Ultra Copper® Maximum Temperature RTV Silicone Gasket Maker.

I have been running like this for 20K miles with no problems: 35MPG at 70MPH. Engine was rebuilt by Metric Motors and was installed in this configuration (i.e. no EGR since rebuild).

I hope this helps someone kill their evil EGR. Mine was stuck open and it took we three washes with very flammable solvents and special-order brushes to get the inside of the manifold clean.

[kinghais]

wow looks great, i gotta try that

[GreenDiesel]

This is what I eventually want to do. Right now I have the butterfly valve stuck open using wire. I also disconnected the vacuum components. All I have are the black and translucent vacuum lines going to the VCV with the ports to the EGR system blocked off and the atmosphere remaining operational. As far as I could see the only operation for the VCV is now for the transmission? Could you elaborate on the control for the crossover and resonance manifold?

I'm thinking when I remove the extension with the butterfly flap I will just try and find one of those cheesy cold air intake pipes with the right diameter and use a hack saw to cut it to length.

Thanks for the pictures and write-up and what a damn fine looking engine bay! CLEAN!!!!

[connerm]

nice work. so the new alum piece is just a pressure fit into the famale x-over pipe? No o-ring? The stock connection, with that little piece that fits inside the two other pieces is a square biatch to put together.

[freesoul]

I would also recommend removing the cone shaped plastic piece in the airbox that restricts flow.