Dave,

There is a metal clip that sits on bolt for the tensioner shock and seems to head over toward the bolt for the spring, but it does not engage the bolt for the spring.

Any idea what this clip does? It is clearly visible in your photo. Mine has the same thing.

Thanks for the cleanest OM603 setup... I would love to see an example of the 'cleanest' OM617.95 setup.

Thanks!

JMH

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Current Diesels:
1981 240D (73K)
1982 300CD (169k)
1985 190D (169k)
1991 350SD (113k)
1991 350SD (206k)
1991 300D (228k)
1993 300SD (291k)
1993 300D 2.5T (338k)
1996 Dodge Ram CTD (442k)
1996 Dodge Ram CTD (265k)

Past Diesels:
1983 300D (228K)
1985 300D (233K)

Well, I have to admit that I have not fully cleaned up all the hose on the SD yet. When I do it, I'll take a shot of it and post it. But, I might be embarrassed to do that because my 617 looks nothing like Dave's 603

LOL! Don't worry... my engine isn't that clean anymore. The photo was taken right after the new head was installed, which is why there's no dirt or dust... I wish it still looked like that!

is this kit still available ?

i don't feel like reading through all the posts so what do you exactly get in this kit ?

give me your paypal address as well.


thanks

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Audi TT

Brian, I received my kit several days ago. Very professional looking, and the detailed instructions are much appreciated. I suspect that your engine egr valve may be easier to access? My 240D has it under the intake manifold, and very tight access to it and the exhaust manifold connection. My remanufactured engine from MB is still under warranty, and functioning well since I plugged the vacumn line to the valve - thereby eliminating clouds of intermittent black smoke that occured on kick-down acceleration. So I think I'll wait to install the kit. The diagnosis of sticking egr valve proved correct, and I probably could have had the valve replaced under the warranty, but all the discussion on this site convinced me otherwise.

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DHB

David,

Yes, the 617 and the 603 both have the valve right up near the top of the engine on the passenger side. I does sound a bit odd that the 616 had the valve underneath the manifold. However, if you can get to it, the replacement intake plate will almost surely fit. The exhaust diameter is also the same as the 617, however, the shape of the nose of the pipe has not been confirmed. It would be unlike M/B to have a different configuration, however.

Brian, Since writing you today, I took off the egr on my e300 '97 and found it to be gummed up with the exhaust crap as expected. The vacuum diaphragm was still intact and after a thorough clean out with "carb out" spray, and oiling the shaft, it seemed to be in perfect working order again. It took a little driving to get the temp up and the vacuum fully loaded again, and the 'cel' went out. It came on again when the engine was shut off, to show me that it had been recorded, but then was gone when I restarted the enging again. It seems to be gone for now.
My advice for those who are not going to block it out is to remove, clean and oil it every 25 or 30 k miles. To replace it costs $326-411 depending on where you buy it. That does not include labor if you have it done.
I am still interested in blocking the exhaust port and putting a filter on that end to allow only outside air in the system. Can't plug the vacuum on the 210 series as that will trigger the 'cel'. Please let me know if the kit is still available. (I only need one plate. I will work on a filter if no one has done this) Thanks, Harvey

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hlg

Lazy......

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Enough about me, how are you doing?

Mine came yesterday. Nice work! Thanks!

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Never a dull moment at Berry Hill Farm.

Manners . . .

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Steve
'87 300TD - 132K - Soon 4-Sale
'84 300D Turbo - 122K - Driving
'77 VW Type II - 77K - Restored
'08 250EX Ninja
English Bulldog (Brier) - My best friend. Passed away 12/02/04 while in my arms.

Randy, you are welcome.

Gifts for Lilly and Marlene, I presume?

Just had another idea, I would like to run by your egr consultants:

Instead of disconnecting on the exhaust side, try this. Just disconnect the intake joint, make either an aluminum or stainless plate for that port and bolt the egr right back over it. The bolts are plenty long and that will close system. However, since the exhaust port is still open, the pressure will open the egr valve, although no gas will flow (except perhaps a smidge will flow up the egr shaft and thus escape--should be minor). Since it is the upward thrust of the valve, that triggers the sensor(not air flow), that should satisfy the computer that the system is working.
Any comments will be appreciated. Harvey

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hlg

For sure. Thanx again for all your hard work.

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Never a dull moment at Berry Hill Farm.

Harvey, I don't see why that would not work. There are W210 members on the board who have experience with disconnecting the EGR and some have posted regarding it. Try a search and see if you can find them.