FYI, this is an excellent kit, and well worth the $. Brian supplies a VERY nicely finished plate and good looking hardware, plus a MB gasket, the necessary copper disc to plug the EGR port in the exhaust manifold, and thorough directions. VERY easy install. I drilled and tapped the EGR plate to accommodate a hose barb for a pressure port to run my pressure-type wastegate actuator (a mod I had been working on with the help of gsxr's excellent thread).

Thanks for providing this kit. I COULD have scraped together the raw materials to do this myself, but the finish would not have been nearly as nice and I'd have spent a lot of time coming up with the right pieces.

__________________
1992 300D 2.5T
1980 Euro 300D (sadly, sold)
1998 Jetta TDI, 132K "Rudy"
1974 Triumph TR6
1999 Saab 9-5 wagon (wife's)

I am very curious about the mods necessary for Cali 617 turbo. I just blocked the valve today, but ended with an exhaust leak b/w the trap ox / cat and exhaust mani.
If you remove the valve completely there is no elegant or effective means of blocking off the cat.

__________________

Yes, that is a problem. AFAIK, there is no easy way of blocking the exhaust outlet from the cat. The copper disc that I provide with the kit won't work at that location. You'd probably have to weld it shut with a steel plate.

Begging your pardon, Brian, your copper disk fit perfectly in the EGR outlet of the trap cat on my '85 300D-T (California version).

Jeremy

Attached Thumbnails

     

__________________

"Buster" in the '95

Our all-Diesel family
1996 E300D (W210) . .338,000 miles Wife's car
2005 E320 CDI . . 113,000 miles My car
Santa Rosa population 176,762 (2022)
Total. . . . . . . . . . . . 627,762
"Oh lord won't you buy me a Mercedes Benz."
-- Janis Joplin, October 1, 1970

Thanks Jeremy.

I've therefore got conflicting info regarding the CA vehicles. Some have the same interface as the Federal vehicles as shown in your photos, and some do not.

Oh well...........it's touch and go with those vehicles with regard to function.

I wonder if the "trap oxidizer" (which had to be changed every 30,000 miles) was externally different from the "trap catalyst?" My car has the "catalyst;" I've never seen the older "oxidizer."

__________________

"Buster" in the '95

Our all-Diesel family
1996 E300D (W210) . .338,000 miles Wife's car
2005 E320 CDI . . 113,000 miles My car
Santa Rosa population 176,762 (2022)
Total. . . . . . . . . . . . 627,762
"Oh lord won't you buy me a Mercedes Benz."
-- Janis Joplin, October 1, 1970

What are the identifying numbers on your catalyst? I am trying to determine if my 'football' has been swapped yet. The car is new to me and I can't tell which one it is (1985).

__________________

I believe it has been replaced w/ the catalyst. Dealership confirms "no outstanding recalls" with one completed.

Here are the numbers on my trapox / cat / football: 126-490-34-14.. this also confirmed by another post where another member posted these numbers.

Thank you all. now how the he^& do I get it out of there?

__________________

I machined a plug in my lathe that fit in the manifold hole , but also had a small lip and put the stock clamp back on ...it looks reaally clean .
I also machined up a plate to cover the EGR ...that looks good too .
I will post some picks when I have a chance .

greg

__________________
1983 300cd

I had the exhaust manifold hole threaded for a pipe cap.
Brian's plate looks clean on the intake.
The only possible improvement might be a Mercedes logo on the plate.

Interesting process...
I was wondering if a couple of these disks and an extra clamp would work to simply block the exhaust gases with out removing the EGR on a 98 E300D??...

Thank you for your time...

__________________
Joe

1998 E300D turbo 240K + Miles
2000 Dodge Dakota 122K + Miles
1992 Mazda Miata Autocross Machine 143K + Miles
http://www.renegademiata.net

Any man who is under 30, and is not a liberal, has no heart; and any man who is over 30, and is not a conservative, has no brains. - Winston Churchill

You can't block the EGR on a computer controlled engine without causing a code. The engine then dumps all boost and the vehicle won't perform.

Some folks have successfully plumbed filtered air to the EGR valve..........the system doesn't know the difference between exhaust gas and filtered air.

Aha...
Does that air supply have to be pressurized?? I'm assuming clamping a filter to inlet wont do the job, that the air needs to come from the turbo outlet....
I cleaned my intake last week and it is like driving a different car, efficient and powerful...
I would rather not have to do that job again.. .

Thanks for the info...

__________________
Joe

1998 E300D turbo 240K + Miles
2000 Dodge Dakota 122K + Miles
1992 Mazda Miata Autocross Machine 143K + Miles
http://www.renegademiata.net

Any man who is under 30, and is not a liberal, has no heart; and any man who is over 30, and is not a conservative, has no brains. - Winston Churchill

Here is what you need to make.

Attached Thumbnails

 

Would that work on the Turbo Charged Engine???

Inquiring minds want to know....

__________________
Joe

1998 E300D turbo 240K + Miles
2000 Dodge Dakota 122K + Miles
1992 Mazda Miata Autocross Machine 143K + Miles
http://www.renegademiata.net

Any man who is under 30, and is not a liberal, has no heart; and any man who is over 30, and is not a conservative, has no brains. - Winston Churchill