EGR removal for '85 California 300TD
EGR removal for '85 California 300TD
01-17-2010, 01:48 PM
#1
so I'm on to step 1.2 - EGR removal. (for testing purposes off course)
for those who don't know, EGR on the '85 Calif car differs from the earlier cars because it has the "vacuum amplifier" (#125) in the diagram that controls something on the 722.4 transmission. Also this model IP has a few extra inputs compared to the earlier ones (just on late MW pumps or are they all the same?)
The goal is to reduce the vacuum to a minimum.
- remove #60 - EGR pipe, actuator; cap manifolds appropriately
- unplug #71 - ARV
- remove control unit and associated wiring harness (will need to rewire tach,
boost aneroid switchover valve and misc other stuff that's included)
- unplug rack position sensor from wire harness
Still some questions:
This leaves me with a couple switchover valves and the vac amplifier for tranny which though simpler, will still be messy looking.
Do I need the vacuum amplifier?
Which parts of the MW pump do I need to keep hooked up?
'85 California EGR courtesy of Peach Parts
-Christian
-------------
'84 G-Wagen turbodiesel
'75 240D 4-Speed
I have most of the engine conversion bugs sorted out from my conversion and am ready to start modifying the engine.
so I'm on to step 1.2 - EGR removal. (for testing purposes off course)
for those who don't know, EGR on the '85 Calif car differs from the earlier cars because it has the "vacuum amplifier" (#125) in the diagram that controls something on the 722.4 transmission. Also this model IP has a few extra inputs compared to the earlier ones (just on late MW pumps or are they all the same?)
The goal is to reduce the vacuum to a minimum.
- remove #60 - EGR pipe, actuator; cap manifolds appropriately
- unplug #71 - ARV
- remove control unit and associated wiring harness (will need to rewire tach,
boost aneroid switchover valve and misc other stuff that's included)
- unplug rack position sensor from wire harness
Still some questions:
This leaves me with a couple switchover valves and the vac amplifier for tranny which though simpler, will still be messy looking.
Do I need the vacuum amplifier?
Which parts of the MW pump do I need to keep hooked up?
'85 California EGR courtesy of Peach Parts
-Christian
-------------
'84 G-Wagen turbodiesel
'75 240D 4-Speed
01-17-2010, 05:05 PM
#2
As far as the MW concerned, just leave #64 unplugged.
.
Gota love Mercedes Diesels!
.
DeliveryValve
01-17-2010, 05:05 PM #2Here is a diagram that I made up to remove the EGR and ARV vacuum line in a stock '85 300SD and 300D models. This leaves the transmission vacuum lines intact so it will have the same functionality as the factory.
As far as the MW concerned, just leave #64 unplugged.
.
Gota love Mercedes Diesels!
.
ForcedInduction
01-17-2010, 07:33 PM
#3
You can always eliminate it all and revert to a pre-84 system.
01-17-2010, 07:34 PM
#4
(01-17-2010, 05:05 PM)DeliveryValve Here is a diagram that I made up to remove the EGR and ARV vacuum line in a stock '85 300SD and 300D models. This leaves the transmission vacuum lines intact so it will have the same functionality as the factory.
As far as the MW concerned, just leave #64 unplugged.
.
Wonderful! thanks. I'll ask the question about the vacuum amplifier in the drivetrain forum.
This post was last modified: 01-17-2010, 07:35 PM by Syncro_G.
-------------
'84 G-Wagen turbodiesel
'75 240D 4-Speed
(01-17-2010, 05:05 PM)DeliveryValve Here is a diagram that I made up to remove the EGR and ARV vacuum line in a stock '85 300SD and 300D models. This leaves the transmission vacuum lines intact so it will have the same functionality as the factory.
As far as the MW concerned, just leave #64 unplugged.
.
Wonderful! thanks. I'll ask the question about the vacuum amplifier in the drivetrain forum.
-------------
'84 G-Wagen turbodiesel
'75 240D 4-Speed
08-13-2011, 03:52 AM
#5
freedivehi
08-13-2011, 03:52 AM #5So? How'd it go? I always envied how much faster my grandma's 84 is than my 85 california.
08-13-2011, 08:21 AM
#6
1984 300D 4-speed ~200,000 miles
7.5mm M-pump, GT3582 turbo, F-Tune Performance intake/exhaust manifolds, A/A intercooler, 315 nozzles, Enlarged prechambers, Bosch 044 feed pump, Custom lightweight flywheel with 240mm clutch, Lowered, 17" AMG rims - 300 hp OM617 project
1985 300D 280,000 miles RIP
2001 F350 7.3 DP tuner, 4"exhaust, S&B intake
led-panzer
08-13-2011, 08:21 AM #6The first thing I did was follow these instructions and blocked my EGR, didn't notice much of anything. The evil trap ox has to go to see any gains....
1984 300D 4-speed ~200,000 miles
7.5mm M-pump, GT3582 turbo, F-Tune Performance intake/exhaust manifolds, A/A intercooler, 315 nozzles, Enlarged prechambers, Bosch 044 feed pump, Custom lightweight flywheel with 240mm clutch, Lowered, 17" AMG rims - 300 hp OM617 project
1985 300D 280,000 miles RIP
2001 F350 7.3 DP tuner, 4"exhaust, S&B intake
08-13-2011, 01:15 PM
#7
(08-13-2011, 03:52 AM)freedivehi So? How'd it go? I always envied how much faster my grandma's 84 is than my 85 california.
It went well, lol, that was quite a while back.
It didn't result in any hp gain but that wasn't really the point. I just wanted simplicity and reliability.
It went from '85 calif car to '84 calif car to federal setup and now almost ready to drop in a VNT with w115/w123 pre EGR manifold setup. Just piecing together the exhaust downpipe before bolting up.
edit: I should add that if you're grandma's car was faster, it's probably just in tuning and filters.
cheers,
Christian
This post was last modified: 08-13-2011, 01:22 PM by Syncro_G.
-------------
'84 G-Wagen turbodiesel
'75 240D 4-Speed
(08-13-2011, 03:52 AM)freedivehi So? How'd it go? I always envied how much faster my grandma's 84 is than my 85 california.
It went well, lol, that was quite a while back.
It didn't result in any hp gain but that wasn't really the point. I just wanted simplicity and reliability.
It went from '85 calif car to '84 calif car to federal setup and now almost ready to drop in a VNT with w115/w123 pre EGR manifold setup. Just piecing together the exhaust downpipe before bolting up.
edit: I should add that if you're grandma's car was faster, it's probably just in tuning and filters.
cheers,
Christian
-------------
'84 G-Wagen turbodiesel
'75 240D 4-Speed
08-13-2011, 02:05 PM
#8
What's your plan on controlling the VNT? I have thoughts on using the rack position sensor (#64) and commissioning an electronics expert to control it.
.
Gota love Mercedes Diesels!
.
DeliveryValve
08-13-2011, 02:05 PM #8Christian,
What's your plan on controlling the VNT? I have thoughts on using the rack position sensor (#64) and commissioning an electronics expert to control it.
.
Gota love Mercedes Diesels!
.
08-13-2011, 07:38 PM
#9
(08-13-2011, 02:05 PM)DeliveryValve Christian,
What's your plan on controlling the VNT? I have thoughts on using the rack position sensor (#64) and commissioning an electronics expert to control it.
I posted an earlier version of my controller on the mechanical VNT control thread (btw, it's that thing above the turbo manifolds in the picture above)
(here: http://www.superturbodiesel.com/std/show...348&page=3)
It's been refined a bit more since my last post but am holding out until I get the thing installed and verify that it works as I hope.
It's an embellishment on FI's valve control setup. I'm linking the valve spring tension to throttle travel.
I thought of doing what you're saying - make some electronic controller that senses throttle or rack position but this spring valve idea popped into my head so I decided to try it first.
This post was last modified: 08-13-2011, 07:40 PM by Syncro_G.
-------------
'84 G-Wagen turbodiesel
'75 240D 4-Speed
(08-13-2011, 02:05 PM)DeliveryValve Christian,
What's your plan on controlling the VNT? I have thoughts on using the rack position sensor (#64) and commissioning an electronics expert to control it.
I posted an earlier version of my controller on the mechanical VNT control thread (btw, it's that thing above the turbo manifolds in the picture above)
(here: http://www.superturbodiesel.com/std/show...348&page=3)
It's been refined a bit more since my last post but am holding out until I get the thing installed and verify that it works as I hope.
It's an embellishment on FI's valve control setup. I'm linking the valve spring tension to throttle travel.
I thought of doing what you're saying - make some electronic controller that senses throttle or rack position but this spring valve idea popped into my head so I decided to try it first.
-------------
'84 G-Wagen turbodiesel
'75 240D 4-Speed
08-17-2011, 12:33 PM
#10
(08-13-2011, 08:21 AM)led-panzer The first thing I did was follow these instructions and blocked my EGR, didn't notice much of anything. The evil trap ox has to go to see any gains....
Ah yes the trap ox! Where might I find out about eliminating that sucker? Any good threads you could pass along?
freedivehi
08-17-2011, 12:33 PM #10(08-13-2011, 08:21 AM)led-panzer The first thing I did was follow these instructions and blocked my EGR, didn't notice much of anything. The evil trap ox has to go to see any gains....
Ah yes the trap ox! Where might I find out about eliminating that sucker? Any good threads you could pass along?
08-17-2011, 12:46 PM
#11
(08-17-2011, 12:33 PM)freedivehi(08-13-2011, 08:21 AM)led-panzer The first thing I did was follow these instructions and blocked my EGR, didn't notice much of anything. The evil trap ox has to go to see any gains....
Ah yes the trap ox! Where might I find out about eliminating that sucker? Any good threads you could pass along?
Easy, somewhat expensive and keeping the stock look way...
Trap Cat Bypass
The other way is to install Federal manifolds... preferably the non-EGR types. But you'll have to deal with air cleaner replumbing/modifications, reclocking the turbo if possible and oil line issues.
.
.
Gota love Mercedes Diesels!
.
DeliveryValve
08-17-2011, 12:46 PM #11(08-17-2011, 12:33 PM)freedivehi(08-13-2011, 08:21 AM)led-panzer The first thing I did was follow these instructions and blocked my EGR, didn't notice much of anything. The evil trap ox has to go to see any gains....
Ah yes the trap ox! Where might I find out about eliminating that sucker? Any good threads you could pass along?
Easy, somewhat expensive and keeping the stock look way...
Trap Cat Bypass
The other way is to install Federal manifolds... preferably the non-EGR types. But you'll have to deal with air cleaner replumbing/modifications, reclocking the turbo if possible and oil line issues.
.
.
Gota love Mercedes Diesels!
.
08-18-2011, 12:35 AM
#12
(08-17-2011, 12:46 PM)DeliveryValve Easy, somewhat expensive and keeping the stock look way...
Trap Cat Bypass
The other way is to install Federal manifolds... preferably the non-EGR types. But you'll have to deal with air cleaner replumbing/modifications, reclocking the turbo if possible and oil line issues.
Reclocking is easy as long as the turbo housing isn't frozen.
-------------
'84 G-Wagen turbodiesel
'75 240D 4-Speed
(08-17-2011, 12:46 PM)DeliveryValve Easy, somewhat expensive and keeping the stock look way...
Trap Cat Bypass
The other way is to install Federal manifolds... preferably the non-EGR types. But you'll have to deal with air cleaner replumbing/modifications, reclocking the turbo if possible and oil line issues.
Reclocking is easy as long as the turbo housing isn't frozen.
-------------
'84 G-Wagen turbodiesel
'75 240D 4-Speed
08-18-2011, 07:02 AM
#13
(08-17-2011, 12:33 PM)freedivehi(08-13-2011, 08:21 AM)led-panzer The first thing I did was follow these instructions and blocked my EGR, didn't notice much of anything. The evil trap ox has to go to see any gains....
Ah yes the trap ox! Where might I find out about eliminating that sucker? Any good threads you could pass along?
Take the car to your local dealer.
1987 300D Sturmmachine
1991 300D Nearly Perfect
1985 300D Weekend/Camping/Dog car
1974 L508D Motoroam Monarch "NightMare"
OBK #42
(08-17-2011, 12:33 PM)freedivehi(08-13-2011, 08:21 AM)led-panzer The first thing I did was follow these instructions and blocked my EGR, didn't notice much of anything. The evil trap ox has to go to see any gains....
Ah yes the trap ox! Where might I find out about eliminating that sucker? Any good threads you could pass along?
Take the car to your local dealer.
1987 300D Sturmmachine
1991 300D Nearly Perfect
1985 300D Weekend/Camping/Dog car
1974 L508D Motoroam Monarch "NightMare"
OBK #42
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