So, I tap the copper plate onto the flange, then pull it off and coat the iside with that stuff, then put it back on and clamp it??

Is that right?

That's exacty right. The only qualification is that you do NOT tighten the bolt on the clamp very tight. Just enough to secure the plate. In fact, if you really try, you can just barely rotate the clamp if you have tightened it properly.

An update on the kits:

Both the 603 and the 617 have the copper discs installed with the Permatex sealant and both have no leaks. I am satisfied that the solution will be decent for the long term.

I will be manufacturing the intake plates and exhaust discs next week. The stainless button head cap screws are in and the gaskets are expected early next week.

I will provide the kit with or without the sealant. If you already have suitable, hi-temp sealant for the copper plate then the cost for the kit is $25.00. If you want the Permatex sealant (99% will be left over) the cost of the kit is $30.00. Your choice.

If you have not already done so, now is your last chance to e-mail me for a kit at: hpcs@csi.com.

If you have previously sent an e-mail, you are on the list. You do not need to send another e-mail.

I will contact everybody via e-mail when the kits are ready for shipment

An update on the kits:

The intake plates and exhaust discs will be completed by Monday.

The gaskets should be in by early next week.

The stainless button head screws are here.

I have ordered a quantity of the Permatex sealant and got a good price on it. Therefore, for whomever needs the sealant, and it is required to be leakproof, the additional cost will only be $3.00. So, the kit price, delivered, will be $25.00 without the sealant and $28.00 with the sealant.

If you are unsure if you have sealant that is good for 700 degrees or more, then you are strongly encouraged to buy the sealant with the kit.

I'll be e-mailing everybody today.

Check's in the mail, Brian!

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AlexTheSeal: hack mechanic, inadvertent drifting champ, builder of infernal devices, professional epistemologist

'87 300D Turbo, roadtrip mileage champ (for sale!)
'92 Isuzu Trooper, mudder extraordinaire (for sale!)
'82 Honda Silverwing, cockroach of motorcycles
And various boring daily drivers...

Will this mod work on the 606 turbodiesel engine?

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'99 E300D (US Spec), 123K

Unfortunately, I cannot provide any input on the 606. Someone who has both the 606 and 603 or 617 might be able to provide an answer. The EGR valve mounting surface has to be the same and the exhaust port for the EGR valve has to be the same as the older engines in order for the kit to function.

I am fairly certain it will not work on the 606 turbo without additional electronic modifications to fool the computer, and that's if it will physically work. From looking at the EPC, it's possible the 606 turbo could use two of the round discs to eliminate the exhaust feed pipe. You can't use the blockoff plate because the EGR valve is integrated into the mixer housing, unlike the 603, where the EGR valve and mixer housing are two separate parts.

The kit may work fine on the 606 non-turbo, used from 1995-1997. At least it seems that way from the EPC...

Don't know if this question has been asked or not, but how, if any affect will this have on the performance of the vehicle?

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Enough about me, how are you doing?

If your EGR valve was functioning correctly, you may notice improved part-throttle power and a little MPG increase. If the EGR valve was non-functional and not leaking, there will be no change. If your EGR was non-functional but leaking (exhaust into the intake), there may be a noticeable performance gain, depending on how bad the leak was (i.e., slight leak, or fully stuck open, etc).

Don't think of this as a smoking gun to gain power, think of it as keeping your intake clean, ALDA circuit crud-free, saving a few pounds of useless weight, cleaning up the engine compartment with fewer components and hoses, while possibly giving a smidge of power/MPG in return!

GSXR,

Thanks for the reply.

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Enough about me, how are you doing?

Your check is in the mail (for two kits)!

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Never a dull moment at Berry Hill Farm.

The first group of kits is on the road.

The second group goes out today.

Enjoy them.

Let me know if you have any problems or need any additional advice.

Brian, just got my kit - very nice, you're the man! One question others may have..the metal gasket included, do the ridges face toward the intake manifold or the stainless plate? Again, great work on this and just in time to add to my rebuilt engine, which God willing will start up and run this weekend

Pete,

Since the replacement plate and the manifold are both dead flat, it won't matter which side the ridge is on. It should seal properly either way.

Good luck with it. Remember the difficulty of the clamp for the exhaust plate. Be very careful not to cross thread it, otherwise you are out of business, and, you cannot operate the vehicle!!