I'm sorry for asking what appears to be such a simple question - but I've searched and I can't seem to find a reason why I can't get the crossover pipe off my 95 E300.

All my experience has been on '92-93's E300D's...

It appears in order to remove the crossover pipe the single bolt on the drivers side (connecting the crossover with the IM) must be removed as well as the bolts on the passenger side (to allow it to swing off).

I've taken the above mentioned bolts off and I can only get the crossover pipe to move 1/4 of an inch but it wont come off. I've tried to be a little rough with it in case it was stuck/etc - but nothing. I've taken a plastic mallet to try to urge it off - nothing.

What am I missing? I'm sure it's something simple.

Thanks,

-John

John, that is all that needs removing in order to remove the cross over pipe.
The two o'rings on the drivers side are sometimes hard and crusty. Just give it a good jerk on the passenger side (side connecting to air filter box) and it should break free.

Don't forget about the vacuum hose going to the manifold flaps located underneath the cross over pipe - it will have to be removed to lift the IM off but it won't prevent you from being able to lift it off 6 inches or so.

Ben

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1995 E300 Diesel

Thanks Ben. Which end should I be able to break free first? Driver side or passenger?

I guess what I'm asking is - with the crossover pipe connected - which end should I attempt to disconnect first? Or does it matter.

It will be easier to pull the passenger side (well for you guys in the US, it's the drivers side for me) or the side connected to the air filter box.

I'm presuming you have removed the flexible hose going from the air filter box to the crossover pipe? It has a large hose clamp attached to it..otherwise you are trying to lift the air filter box as well.

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1995 E300 Diesel

Thanks - I'm going to give it another try tomorrow.

dont forget the EGR connection. As mentioned the O-rings at the manifold may be crusty, have some patience and wiggle it back and forth. I take all 6 bolts out on the passenger side which makes it easier. Only takes 5 min once you do it a few times.

to reinstall I use a rubber mallet and wooden dowel an apply some whacks in the area by the bolt connecting to the manifold. Don't forget to replace your vacuum hoses! Also while you have it off, remove and clean the resonance flap it may be stuck. If you pull the intake manifold you should remove and clean that resonance flap as well. Both of mine were crusted and barely moved with vacuum applied, when cleaned up and functioning properly the car runs much better.

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1995 E300 diesel

When you put the IM back on, take care not to over tighten that bolt on the drivers side. It will strip easily - not sure of the correct torque, but it's got to be less than 20 N or something. Don't ask how I know...

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Charlie

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'66 VW 1300 96K miles
'97 E300D 239K miles
'85 300D 203K miles (sold Sep 2012)

Wanted to say thanks to everyone. Got the IM off once I had the passenger side bracket off. I guess I had assumed the IM pipe would come off without taking off the bracket.

Thanks again. Glow plugs are now repaired.