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Diesel Purge can and does make a difference if the things it resolves impact performance. If the system has never had it run through, it DOES get rid of varnish and buildup in the injection pump and DOES make a difference in power and operational smoothness.
The spin-on fuel filter is seriously a pain. I share your opinion of it 100%. There are plenty of other places they could have mounted the thing or moved something else to give clearance to get the damn thing out without spilling it everywhere.
I've reused the crossover pipe gasket more than once. As long as it isn't in horrible condition, you can likely reuse it without issue. If you think the crossover pipe is bad, you should see the rest of your manifold. If the EGR system is functioning, you've likely got a HEAVY buildup of carbon in the intake runners. If you pulled the manifold, you'd probably be surprised the engine runs as well as it does!
The outside of the injectors isn't that important. It's what's inside that matters. Ao long as they're clean inside and free of rust and corrosion, you're good reusing them. Make sure you have the sandpaper and glass handy to lap the mating surfaces or expect leaks.
A really good "solvent" to get rid of the carbon cake is gun solvent. It's sole purpose is to dissolve carbon, oil, and lead remnants. Soak a Q-tip and rub, it should just melt off. Clean up afterwards with your favorite spray solvent.
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Current stable:
1995 E320 157K (Nancy)
1983 500SL 125K (SLoL)
Gone but not forgotten:
1986 300SDL (RIP)
1991 350SD
1991 560SEL
1990 560SEL
1986 500SEL Euro (Rusted to nothing at 47K!)
Gone and wanting to forget:
1985 524TD 167K (TotalDumpster™) [Definitely NOT a Benz]
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