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Originally Posted by pcmaher
All filters new except the expensive activated charcoal filter. Since that works only in recirc, and recirc works fine, I don't think it's clogged.
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Activated charcoal filter can be turned on or off in either normal or recirc mode by button in early W140s, or automatically by smog sensor in a later cars.
I would doublecheck the recirc flap to make sure it opens all the way and stays open in normal mode. I had same problem you experiencing, and found the linkages from both vacuum elements to that flap were disconnected.
Mike