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1) It would be a help if you created a signature with your car's year & model, and maybe your name. Or at least include that info in your post. I assume you have a 1990-1993 300D 2.5 Turbo though.
2) You cannot simply disconnect the EGR on the 90-up engines. The EDS will know you killed it, and will prevent boost from building by keeping the wastegate open. There is a way to disable and/or remove the the EGR but it requires either fooling the electronic sensors, OR replacing your turbo wastegate with the older mechanical pressure type. Both procedures have been done successfully by members of this forum - use the "Search" feature.
3) The flap in the intake doesn't change "vacuum" because there is no vacuum in the turbo charge (intake) manifold. What it does is similar to the old air recirc valves, I believe, where it reduces boost pressure to allow more exhaust gas to enter the intake stream. Otherwise the turbo boost would reduce the flow of exhaust into the pressurized intake stream.
4) The overboost protection is totally separate. It has a sensor in the intake manifold which triggers at, IIRC, 1.10 bar +/- 0.15 bar. When that happens, it kills fuel enrichment by cutting off the signal line to the ALDA. This is what happens if the wastegate fails and sticks closed, providing too much boost.
5) You need to test your car from 0-60mph with a stopwatch on flat road. It should be about 11-12 seconds. If not, you're down on power, and probably need to either reconnect the EGR, or disable it correctly as mentioned in item #2 above.
HTH,
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