The 1995 (also 1994 in Europe and the UK and Other Places?) E300D has a unique manual shut-down control. Unlike earlier OM60x diesels that have a shutoff lever on the IP or later models that use an electric shutoff valve, the 1994-95 version has a manual fuel shut-off valve in the fuel filter assembly. Should the vacuum shutoff on the IP fail, this valve can be closed, cutting off fuel to the IP and stopping the engine.

The E300D that I just bought came without such a valve. I bought one and installed it but it did not work. There is no reason why it should not work -- no missing o-rings or mis-routed fuel lines. Yes, I screwed it the right way and left it screwed closed while the engine sat there happily idling.

In its place, a friend suggested that I use the existing shutoff on the IP, which is just like the ones on the earlier OM60x engines except there is no shutoff lever on it. I even had an extra OM603 IP sitting around to play with. Here's what I did.

First, I hunted through my junk boxes until I found a scrap of aluminum the right size and thickness -- about 3 inches long, 3/4 inch wide, and 1/4 inch thick. I carefully drilled and filed a rectangular hole to fit over the shaft of the IP's shutoff valve and added a long screw to act as a clamp. Since the location of the shutoff on the OM606NA is buried under the intake manifold, a piece of heavy coat-hanger wire was added on a swivel joint so that it reached up through the manifold. (The center hole of the aluminum scrap was there from the scrap's previous incarnation.)







To cover the coat-hanger wire and prevent rattles I found a piece of scrap black plastic tubing and finished it off with a red cap that once covered the end of some copper tubing. The curve in the black plastic tubing was from being stored in a roll; the curve actually helps the tubing stay on the wire without glue.









After replacing the crossover pipe I discovered that the rod was too long and touched the insulation when the hood (bonnet) was closed. This took two iterations of careful trimming to get the length exactly correct. You want the rod short enough to not be pressed when the hood is closed but long enough so it doesn't hang up on the intake manifold. In my car that length is 7-1/2 inches. As usual, YMMV. (The following picture was taken while the rod was still too long.)





I tested my addition by pressing on the rod while the engine idled. Lo and behold, the engine stopped! Now I have an emergency shutoff for this engine, just in case. Total cost: $0.00 (plus my time).

Jeremy

__________________

"Buster" in the '95

Our all-Diesel family
1996 E300D (W210) . .338,000 miles Wife's car
2005 E320 CDI . . 113,000 miles My car
Santa Rosa population 176,762 (2022)
Total. . . . . . . . . . . . 627,762
"Oh lord won't you buy me a Mercedes Benz."
-- Janis Joplin, October 1, 1970

Awesome, you won't miss that in a hurry.

We had E300D's here in Australia in 1993:That is the date on my engine.

Does yours have the manual shutoff valve on top of your fuel pre-filter?

As far as I thought, the E300D had only an electronic shut off at the IP so I wouldn't be able to do something like you have done.

I will have to check when I next have the crossover pipe off.

__________________
1995 E300 Diesel

The fully-electronic IP's did not arrive until the W210 chassis. The 124.131 still has a mechanical governor and shutoff.

PS: You don't need to quote the entire post+photos when replying...

__________________
Dave
Boise, ID
Check out my website photos, documents, and movies!

thanks gsxr, just edited my last post. Is there an easier way than holding down the backspace button to remove the content not wanted from the quote?

__________________
1995 E300 Diesel

I like it...I like it a lot!

1993 E300D: must be 'cause of the International Date Line.

Mine is supposed to have a fuel shutoff valve in place of the center bolt holding the secondary (large) fuel filter in place. That's what EPC shows but my car apparently had its removed or never had one. The second owner said he got the car that way from the original owner in Texas (like Australia but smaller -- but don't tell the Texans). He looked into adding back the valve but stopped after learning the price -- US$140 or so, I believe.

As gsxr writes, the electronic IP did not show up in this country until the 1996 model year, with the W210 chassis and 606.910 engine (I have one of those, too). We Americans tend to forget that Mercedes builds a lot of models and variants that never make it to this country; please forgive us our provincial ignorance. I suppose an early version with electric shutoff could have been marketed in Other Lands a year or two before 1996.

It would not have been that difficult for the factory to build a version of the STOP lever that would work with the 606 intake manifold. I don't know what was going on to make them adopt the valve on the fuel filter approach. One of life's mysteries, I guess.

Jeremy

__________________

"Buster" in the '95

Our all-Diesel family
1996 E300D (W210) . .338,000 miles Wife's car
2005 E320 CDI . . 113,000 miles My car
Santa Rosa population 176,762 (2022)
Total. . . . . . . . . . . . 627,762
"Oh lord won't you buy me a Mercedes Benz."
-- Janis Joplin, October 1, 1970

Haha, ongoing joke with my brother. He married a Texan gal and now lives there with his family. I think our temperatures are similar ( except for the unit of measure in degrees) but he definitely says that Australia's solar radiation is stronger. In the heat of summer with just 10 minutes exposure, we can looked like a cooked lobster.

__________________
1995 E300 Diesel

Looks better now - thanks!


I usually use the mouse to select the portion not wanted and then press the delete key. To avoid quoting at all, either use the "Post Reply" button at the bottom of the thread, or press Ctrl+A to highlight everything and then delete it. I mostly try to avoid having photos in a quote, as it tends to clutter up a thread.

__________________
Dave
Boise, ID
Check out my website photos, documents, and movies!

Great fix Jeremy, and I think I'd trust the IP to more quickly shut down the engine than fuel upstream anyhow!

I guess I've never studied the 606 crossover carefully (never owned one), how does the crossover seal to the 'actual' intake? Looks like there may have been a gasket no longer pictured? MB certainly got creative on all their intake routings.

__________________
05 E320 CDI
99 SL500
02 530i

82 240D SOLD
83 240D Euro 4spd SOLD
86 300D Euro Auto SOLD

The cross over pipe has a pressure fit gasket inside the pipes, the pipe seals pretty hard against it on the manifold. And the other end (airfilter, EGR) there is a aluminium doughnut with two O Rings in it that is placed between the two parts.

@jeremy - GREAT, sure beats the expensive bolt.

__________________
2012 BMW X5 (Beef + Granite suspension model)

1995 E300D - The original humming machine (consumed by Flood 2017)
2000 E320 - The evolution (consumed by flood 2017)

I don't want to disagree with my friend Zulfigar but I could've sworn there are a pair of black o-rings that seal the connection between the crossover and the intake manifold. . . [Looking] . . . Yes, EPC shows "Seal Ring, Intake line to intake manifold, Qty 2, part number 606 997 06 45." (Sorry, Z., maybe by "pressure fit gasket" you meant "o-ring"?)

Jeremy

__________________

"Buster" in the '95

Our all-Diesel family
1996 E300D (W210) . .338,000 miles Wife's car
2005 E320 CDI . . 113,000 miles My car
Santa Rosa population 176,762 (2022)
Total. . . . . . . . . . . . 627,762
"Oh lord won't you buy me a Mercedes Benz."
-- Janis Joplin, October 1, 1970

I still have the mock-up of a "pull-type" shut-off on my spare 603, from way back when we were first discussing the need for this feature. I was going to leave enough slack in the cable, so that during normal operations, it would just harmlessly loop in an arc as the arm lowered during vacuum shut-offs. But, assuming I can snake a rod up through a hole drilled between the intake runners on my 606.96, I may opt for your simpler and more elegant approach. Again, nicely done.

yes sealing ring - English is not my first language so some bits get lost into translation, its a pressure fit sealing ring.

__________________
2012 BMW X5 (Beef + Granite suspension model)

1995 E300D - The original humming machine (consumed by Flood 2017)
2000 E320 - The evolution (consumed by flood 2017)

So, your first language is . . . Texican? I understand, then.

Actually, "sealing ring" as used by EPC is a translation of the original German word, which I don't know. Without that I would use the term "big o-ring" 'cause that's what it looks like. "Expensive" is also a good word for that part.

Jeremy

__________________

"Buster" in the '95

Our all-Diesel family
1996 E300D (W210) . .338,000 miles Wife's car
2005 E320 CDI . . 113,000 miles My car
Santa Rosa population 176,762 (2022)
Total. . . . . . . . . . . . 627,762
"Oh lord won't you buy me a Mercedes Benz."
-- Janis Joplin, October 1, 1970

hmm - lol not texican, I have a pretty hard time understanding it, specially the country one.

anyways - your translation is perfect - Big Expensive O ring... It would be fascinating to see such a part description in the EPC. Anyway. I have made this my for my car too, sure beats the "expensive bolt"

These parts rants remind me of SAAB parts which are like "this OE SAAB braided fuel hose was made on solid Gold machinery operated by superhumans and the rubber itself is not from this planet"

because the hose was $18/ft.

__________________
2012 BMW X5 (Beef + Granite suspension model)

1995 E300D - The original humming machine (consumed by Flood 2017)
2000 E320 - The evolution (consumed by flood 2017)