First timer replacing vac lines etc...95 E300D - PeachParts Mercedes-Benz Forum

iceman805 · #1 07-29-2007, 03:26 AM

I finally got a clue

as to the location of the pertinent various schematic resources available and between detali.ru, starteckinfo/epc, AllDataDIY and this forum I've got a fairly good grip on replacing all the vacuum pipe, hose, nozzle, throttle, damper etc...for the intake and exhaust system.

I took the detali.ru part number matrix, pasted it into Word and then applied different colors each group of the line items that were the same and placed an order for all the parts. A day later I was able to get the Startekinfo/epc to work, doh!

Side Note:
The parts arrived and I think I under-ordered a 40mm hose (38 detali, 123 997 20 52) I also noticed that startekinfo/epc gives me a secondary schematic that is a closeup of the VCV section that calls for a set of elements I didn't order.

So anyway, tonight I replaced the vacuum connections on the Vacuum Amplifier/Pressure Converter, EGR Switchover and Vacuum Control Flap Switchover. I have two unanswered questions at this point:

The pipe (92 in detali, 000 987 22 67) indicates it should come from the bottom of the EGR switchover through the 4 way branch off fitting (77 detali, 117 078 00 45) via connecter (86 in detali, 602 078 00 47) to vacuum hose (95 detali, 617 997 08 82) to vac pipe 92 and then to VENTILATION. I traced the line and it stops in the battery compartment and is not connected to anything. I looked to see if there was anything from which it might have come apart but didn't see a thing.

Is this the way it's supposed to be?

Also, I can't for the life of me find any documentation on the "Vacuum Control Tap Unit". No part number, reference etc...other than listed in the AlldataDIY diagram. ???

Tomorrow morning I'm taking off the crossover manifold again to replace all the remaining elements in this portion of the vac system. I remember last time that I noted that a unique hose with a protrusion that sits in a slot on the VCV and connects to the green damper. I ordered all the parts and didn't receive a hose that has this characteristic. I don't want to reuse it but not sure what else to do. ??

I hope this was clear enough...I feel like there should be a quicker way of getting to my points but....I just don't know how.

PS. Is there a cheetsheat that lists/identifies items by all of the different names they seem to be called by each of the various resources...for instance:

Electric ChangeOver/Switchover Valves
Crossover/Switchover Manifold
Vacuum Amplifier/Pressure Converter
Vacuum Control Valve, VCV

TMAllison · #2 07-29-2007, 11:31 AM

Quote:

Originally Posted by iceman805

I hope this was clear enough...I feel like there should be a quicker way of getting to my points but....I just don't know how.

You could paste the link. That would help us follow along......

iceman805 · #3 07-29-2007, 01:34 PM

Thanks Terry, please let me know if this is an improvement to presenting my problem to you folks. (I'm trying to follow the posting guidelines in the Sticky and trying like all get out to research my own problems and solutions.)

This is the overall vacuum scematic from which I determined what parts to get. I copied and pasted the part numbers matrix/spreadsheet into MS Word and assigned one of three colors to each group of parts so that it was easier to read how much of each item I needed. I'll post a final parts list when I'm done so it will be as accurate as I can make it.
http://tinyurl.com/2b23yj

This is the vacuum schematic for what looks to be a close up of the VCV connections.
http://tinyurl.com/35bgu5

Startekinfo/epc indicates a different part number for the following item :
(#205) 001 997 81 52 (Russian EPC http://tinyurl.com/35bgu5) is listed as (#275) 116 276 06 30 in the Startekinfo/epc schematic (subgroup 195 of Automatic DB Transmission "Line from Vacuum Box to Vacuum Control Valve")

Does anyone know if these actually different?

A friend of mine answered my first question. When the info indicates that vacuum pipe #92 (http://tinyurl.com/2b23yj) goes to VENTILATION it means that it vents to open air.

The second question had more to do with hoping someone could point me in the direction of information on the Vacuum Control Tap Vacuum unit. I just located it on the Startekinfo/epc schematic and it is also called the Vacuum Box according to Startekinfo/epc. I'll do some searching on Vacuum Box now...
http://tinyurl.com/yopl7o

iceman805 · #4 07-31-2007, 03:23 AM

Did I forget to put my forum deodorant on...(looks under each arm and sniffs)?

1995 E300D with 215,000 miles on her when she found her way home to me. Newbie DIY'er in love with the prospect of restoring my 85 to daily driver status after my foray in the deep end here..wondering if working on my vacuum system mean I'm doomed to work in a vacuum?

I'm 100% for footwork, have tried all the search combinations that my newbie head can conceive in trying to find previous information on my issues but I'm struggling on some peripheral items...stumbling to some success.

First two images are the BEFORE/AFTER shots of the Vacuum Amplifier set of vacuum pipe, hose, throttles etc... that I replaced. All hoses except the getto one attached to the EGR were replaced. If someone could let me know if I should replace that with #that would be reassuring. There was some oil on the Vacuum Tap Vacuum Control Unit and I hope it wasn't indicative of any issue, but I can't find squat on that item.

iceman805 · #5 07-31-2007, 04:30 AM

Next stop was the VCV connections...BEFORE/AFTER. I had a hiccup with the melted splitter at the back of the intake switchover valves. I didn't pull the main manifold so I had to use some long right angle pliers and a mirror... oh yea, then the fun began.

I replaced the existing hose for the stop vacuum unit with what the russian EPC indicated as #20 (http://tinyurl.com/2b23yj) and promptly mixed up the lines that connect to the various a, b and c paths listed as 5,95,5 5 on the right of that diagram. You know, the ones attached to the firewall that I can't trace on any schematics since they all stop on all the diagrams before that point. (see attached, #4 is the line off of the bottom of the VCV)

So I fire her up...so good so far..then turn her off. Opps, guess what line I muxed...yep...I didn't remember to just disconnect it and suck on the line to stop the engine but I did twist the top of the fuel pump (the part that says stop). After that didn't work I reattached the stop vacuum pipe and she shut right down.

So I reconnect the other pipe, I think it came from the switchover valves, reconnect all the crossover, EGR etc... and take her for a spin.

Well, I guess I shouldn't have ought to done that twisting because now I'm stalling on my test drive. Okay, I pop the hood and start turning the knob back the other direction...but how much? I venture a good SWAG (scientific wild ass guess) worth.

Hmmmm, normally I just turn the key and she starts right up but not now...now it requires a bit of the gas peddle to get her going....and I'm back on the road to my parking spot. Pop the hood again... and I note that I've got a nice bubbling spew of diesel trickling from the knob I turned. Oh JOY! Develops into a nice little puddle on the ground under my car. (see attached image)

Well, I spend another two hours on the site looking for search terms like:
vacuum connection firewall
vacuum firewall
vacuum attachments firewall
vacuum connectors
vacuum diaphram
and all of the above with 95 e300d as added terms.

I searched AllDataDIY, Startekinfo/epc and the russian site till it or my provider went down tonight...and still don't have anything more than an ACC diagram indicating a "check valve" #36 that connects to the vac connection on the intake manifold. (can't link it)

So I decide to take another test drive to see if my little diesel fuel experiment had run its course instead of pull my hair out searching for pertinent information.

She ran smooth and the shifts were different than before...I didn't take her on the freeway so I'll check it out in the morning but I think I have everything hooked up properly. The shifts are pretty smooth but I'm not really sure how it is supposed to shift yet.

iceman805 · #6 07-31-2007, 04:37 AM

Next stop will be to take the manifolds in for cleaning(see attachment) ...determine if the fuel lines should be replaced and then find a proper way to clean the entire engine compartment down to the block.

I doubt the glow plugs have been replaced much but I'm not sure they need replacing. The light comes on for about 3-5 seconds and she always starts right up.

Here are some other images of things I need to address.
Manifold and Mixer, Checkvalve at the firewall (looks bad)

TMAllison · #7 07-31-2007, 09:57 AM

In post 5 with the leaking fuel filter housing that leak is comming from your kill switch. It has two orings on its shaft. It was probably overtightened and crushed them.

My 99 uses vacuum very little so am not much help there.

iceman805 · #8 07-31-2007, 12:36 PM

Quote:

Originally Posted by TMAllison

In post 5 with the leaking fuel filter housing that leak is comming from your kill switch. It has two orings on its shaft. It was probably overtightened and crushed them.

My 99 uses vacuum very little so am not much help there.

Thank you very much for enlightening me...figures. Glad to know I was correct about the switch/knob...not so thrilled about my application of too much torque on it. I need to fix that ASAP, right? Since I don't know when the filters were replaced I guess I should just go ahead and replace the main and pre-filter with all the O-rings, correct? I'll do a search on orings and fuel filter etc...to see what I can learn.

Do you have any tips on search terms that would enable me to trace down that vacuum consolidator (for lack of a better/accurate name) at the firewall?

Thanks again Terry!

iceman805 · #9 07-31-2007, 03:25 PM

Bump for WHUNTER, thanks!

TMAllison · #10 07-31-2007, 03:44 PM

Quote:

Originally Posted by iceman805

Do you have any tips on search terms that would enable me to trace down that vacuum consolidator (for lack of a better/accurate name) at the firewall?

Dont know where all the W124 guys are at.

One or two of the vacuum control valves you are talking about are controls for your resonance flaps and egr valve.

You've got your crossover off, etc; give them and the flaps all a good cleaning. They get gummed up on your 606.910 and can cause surging problems and lack of power. Bio99 works well if you've got time to soak it as does brake cleaner on the heavy stuff.

iceman805 · #11 07-31-2007, 08:11 PM

Quote:

Originally Posted by TMAllison

Dont know where all the W124 guys are at.

One or two of the vacuum control valves you are talking about are controls for your resonance flaps and egr valve.

It is the line/pipe that leads to secondary consumers (coming from the forward side of the twin resonance switchover valves using line #56) that I'm trying to trace. I want to be sure the line is connected and working properly but don't want to dismantle it to find out where it goes.

Can anyone tell me if the line/pipe from the VCV using line #50 and terminating in the diagram to hose #5 (second from the right) is supposed to go to Ventilation as well as the one next to it using hose #95?

I know the line to the key stop is connected correctly.

Side note: it was actually a piece of the fuel filter bushing that had torn and was causing the leak. I swapped out the O-rings anyway (put them aside for an emergency) and replaced the fuel filter right behind the dealer. Drove 30 miles back to work and will head home to replace the pre-filter now. It was dry as A BONE!

Quote:

You've got your crossover off, etc; give them and the flaps all a good cleaning. They get gummed up on your 606.910 and can cause surging problems and lack of power. Bio99 works well if you've got time to soak it as does brake cleaner on the heavy stuff.

Yes, I had planned to take the flaps, crossover and intake manifold to an engine overhaul shop in a few weeks but speaking with Roy this morning I decided to replace the fuel lines and do the manifold this weekend. Purchased all the correct parts with expert help....makes me feel like I slept at a Holiday Inn Express last night.

Thanks Terry and thanks again Roy!

WINGAS · #12 08-01-2007, 06:44 AM

A can of Engine Gunk and a "wanda wash" is all thats required for cleaning the manifold.

I've having a hard time followng all the "nomenclature", but if you need a line traced, let me know. My 95 runs flawlessly.

iceman805 · #13 08-01-2007, 11:04 AM

Quote:

Originally Posted by WINGAS

I've having a hard time followng all the "nomenclature", but if you need a line traced, let me know. My 95 runs flawlessly.

Thanks! Let me try to explain this way:

First Diamgram:
The first attached diagram has a small connector colored blue just below the letter "C" that represents "secondary consumers". What are the secondary consumers and how do I check that the connection is correct?

There is also a line colored in blue that appears to come from the side of the VCV in this diagram. Does this attach to a part on the VCV that pivots toward the front and rear of the car? Is this supposed to vent to open air? If not, to what is it supposed to connect?

Second Diagram:
The line colored in blue can also be seen at the Russian EPC diagram http://tinyurl.com/35bgu5 (#205). Russian EPC lists it as part number: 001 997 81 52

Startekinfo/epc indicates it should be this part number: 116 276 06 30

Are they both correct or should I use one rather than the other?

I left it alone when I was in there but when I get the manifold off in the next few days I want all this to be the best it can be. I don't want to cut corners or use parts that "will work".

FYI - the attached images were gifs on my PC but converted to jpg when uploaded...no idea why...gifs should be used for line art like this and jpg should only be used for photos or images with gradients etc..