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Old 05-15-2004, 04:16 PM
Registered User
Join Date: May 2004
Location: Texas
Posts: 228
'96 E300 EGR surge

I need to remove my EGR and block the holes. How is this done with the electrical problems associated with the codes?

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Old 05-15-2004, 05:50 PM
Join Date: Mar 2000
Location: Gainesville FL
Posts: 6,844
To solve the warning lights you will have to fix the problem, most likely.
Steve Brotherton
Continental Imports
Gainesville FL
Bosch Master, ASE Master, L1
33 years MB technician
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Old 05-16-2004, 01:48 AM
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Join Date: May 2004
Location: Texas
Posts: 228
carbon build up problem

carbon build up is the problem. cleaning the intake maifold and the three valves inside the manifold solves the surge problem. I believe that if clean fresh air is in the intake with no exhaust gases the problem will be solved forever. using a biodiesel blend also solves the problem but i want the car to run as it was designed to run with clean air going into the intake.
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Old 05-16-2004, 07:55 AM
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Join Date: Sep 2003
Location: France
Posts: 487
Sorry for this stupid question what is EGR valve?

Are you speaking of Diesel car?
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Old 05-16-2004, 02:42 PM
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Join Date: May 2004
Location: Texas
Posts: 228
EGR removal

Sorry for my lack of word control.
My 1996 E300 (OM606) has a history of surge problems. The dealer has replaced all of the parts that could possibly cause this problem. Under warranty and out of warranty. They even replaced the CPU when the car was out of warranty. This was all before I bought the car.
Now I run on biodiesel (B35) and the surge is gone. But last month I began to try and fix this problem because the supply of biodiesel stoped and I was forced to use 100% of the dirty stuff (mostly Diamond Shamrocks Valero Brand Diesel) So my shop and I began researching this problem. After a week and a half of this a hand written note was found at the local Mercedes Dealer that said if none of the regular fixes did not work a "test plate" should be installed in the return from the EGR to the intake manifold with a hole big enough to stop the surge and small enough not to give an EGR code. I tryed this for a few days and changed the size of the hole 4 times.
Finally I removed the "test plate" and went back to biodiesel. But I now have a "Check Engine" light "Engine Electronics" that the code says is Boost Pressure Regulator.
I have seen threads that suggest either removing the EGR and return flow to the intake manifold or adding a small air cleaner before the EGR so that clean air is returned to the intake.
Either way it seems to me that clean frest air is better than dirty exaust gases in the intake. Please tell me if this is wrong?

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