euro 617 turbo and EGR? how do I patch the intake manifold - PeachParts Mercedes-Benz Forum

Douglas.Sherida · #1 05-06-2007, 06:37 AM

For the record, I'm talking about a 1984 300TD.

It was a gray market import with a 617.952 turbo. The original owner told me that when he went to pick it up from the port (in 84), they would not release the car. I'm assuming that's when this happened. (I can't imagine another scenario whereby someone would do this voluntarily.)

Someone installed an EGR using brass NPT fittings. It was welded into the exhaust manifold and glued into the aluminum intake manifold with high temp silcone sealant.

Question 1) Did a euro turbo originally come with an EGR? If so, how was it mounted to the intake /exhaust manifolds?

Question 2) What are my chances of finding replacement intake/exhaust manifolds like these (without the EGR mounting flanges)?

Question 3) How hot does the intake manifold get? I could just cap the fitting on the exhaust manifold and it wouldn't bother me, but the intake manifold needs to be patched (or replaced). I have recently used low temp aluminum brazing rods to repair some non-automotive aluminum castings with great success. I could envision using the same material to patch this hole, but only if the intake manifold does not exceed 700 F.

t walgamuth · #2 05-06-2007, 07:43 AM

my gut says it will be fine, but i have no science to back it up.

tom w

Mister Byrnzoil · #3 05-06-2007, 09:32 AM

neither of my euro N/As have an egr.

EDIT: and both were 'Properly Federalized'

I would think if you pre-heated the manifold you could weld or braze it.

what a ghetto mess, good luck.

Brian Carlton · #4 05-06-2007, 10:24 AM

Quote:

Originally Posted by Douglas.Sherida

For the record, I'm talking about a 1984 300TD.

Someone installed an EGR using brass NPT fittings. It was welded into the exhaust manifold and glued into the aluminum intake manifold with high temp silcone sealant.

Question 1) Did a euro turbo originally come with an EGR? If so, how was it mounted to the intake /exhaust manifolds?

Question 2) What are my chances of finding replacement intake/exhaust manifolds like these (without the EGR mounting flanges)?

Question 3) How hot does the intake manifold get? I could just cap the fitting on the exhaust manifold and it wouldn't bother me, but the intake manifold needs to be patched (or replaced). I have recently used low temp aluminum brazing rods to repair some non-automotive aluminum castings with great success. I could envision using the same material to patch this hole, but only if the intake manifold does not exceed 700 F.

Q1) I don't believe that any of the Euro vehicles had EGR in that vintage.

Q2) Zero. Get a standard set of intake/exhaust manifolds and use one of my kits to eliminate both the intake and exhaust ports.

Q3) You can certainly braze the hole in the intake manifold. The intake does not get anywhere near 700°F. My guess is that it does not exceed 275°F. even in the worst possible conditions.

Rashakor · #5 05-06-2007, 10:26 AM

Euros turbo or NA versions do not have EGR ever. Actually getting a manifold would not be that difficult if you have some friends in Europe. German, Dutch and French forums are overflowings of ads of this kind, swap meets, parts exchanges, etc...
If you are language-challlenged maybe trying a British website or forum will get you some hard to find, original, unmolested euro parts (dont get Brit headlight though they light the wrong side of the streets

).

#6 05-06-2007, 03:09 PM

Quote:

Originally Posted by Brian Carlton

Q1)Q2) Zero. Get a standard set of intake/exhaust manifolds and use one of my kits to eliminate both the intake and exhaust ports.

Way to market your kit!

There is actually a very good chance of finding a non-EGR set of manifolds. Just find any 79-80 300SD (W116).

Brian Carlton · #7 05-06-2007, 03:10 PM

Quote:

Originally Posted by ForcedInduction

Way to market your kit!

There is actually a very good chance of finding a non-EGR set of manifolds. Just find any 79-80 300SD (W116).

.........yes........very commonly available items........

#8 05-06-2007, 03:22 PM

Quote:

Originally Posted by Brian Carlton

.........yes........very commonly available items........

They are actually. Just look around and eventually you will find some. If you frequent a junkyard with a high turnover, chances are you will eventually find a good set like I did.

Or, you can post a WTB thread in the parts forum and see if anyone has a set to sell you.

winmutt · #9 05-06-2007, 09:40 PM

Quote:

Originally Posted by Mister Byrnzoil

neither of my euro N/As have an egr.

EDIT: and both were 'Properly Federalized'

I would think if you pre-heated the manifold you could weld or braze it.

what a ghetto mess, good luck.

U sure about that? There should be a tube coming from the exhaust manifold into the airfilter. This was the primitive EGR on those NA euros. Atleast my 83.

Douglas.Sherida · #10 05-06-2007, 10:44 PM

I was working on my buddy's aluminum boat today and I managed to score a piece of scrap aluminum stock that will be a perfect plug for the hole in the intake manifold. It already fit the hole perfectly and once its brazed in and ground down chould be almost invisible, especially if I can distress it to match the original casting texture. I'll update with pics when its done.

The exhaust manifold will get capped. I will forget about it soon enough, since its on the bottom and behind the turbo (out of sight = out of mind).

Free, durable repairs always win in my book.