Originally Posted by dhbecker

Brian: I finally installed your kit on my 240D today. Its awkward on this engine because the valve mounts on the underside of the manifold, and the nearby exhaust manifold connection is also cramped to get to. After removing the valve and connecting tube, I solved the problem by cutting the protruding vacumn part from the cast body, screwed the valve body to a block of wood using the mounting holes, and formed the copper disc on the tube connection surface, which is identical to the exhaust manifold connection. By hammering and repeated heating (copper hardens from hammering) I was able to form a lip around the connection similar to the tube connection. The fit was snug albeit not as tight as the tube. After applying the copper sealant, I tightened the clamp snugly (carefully following your screw thread precautions) and I believe the copper was not deformed, and hopefully should not leak. Even the tube connection showed some evidence of slight leakage of soot, so with the sealant I believe it should be a tight seal. I'll find out after it cures for several days. The weather here in Wisconsin is finally starting to break, and maybe I'll be able to get my Benz out of the barn and back on the road by next weekend. One suggestion I might make though for anyone trying this procedure, is to make the copper disc slight larger in diameter in order to form the lip. I was able to "stretch" the copper around the edge by hammering, but a little more diameter might have made it easier.