W210 320CDI OM613 inlet manifold removal - swirl flaps & egr

[St Ives Velo]

I recently noticed that the swirl flap actuating arm was disconnected & thought I would have a go at doing the EGR valve and swirl flaps clean up as they appear to be jammed but not sure if they're open or closed.

Found a couple accounts on what to do but not much detail but it sounded doable so jumped in with both feet and started dismantling....

HELP......Well, boy oh boy it's not so easy.....with only a limited amount of bad language I've got to the stage where the manifold is free and the only thing holding it back is a cable dropping down from the loom on top of the engine down through the manifold and disappearing to the the rear in the bulkhead direction, after some searching I found a connector on top of the gearbox housing which I disconnected, but there is something else holding the cable back, I cut all cable ties I can find and disconnected all connectors I can see, searched for above and below & can't for the life of see see what it is as there's so much in the way. I wonder if this cable splits to connect another component as I can't see anything?

Has anyone done this and have any ideas & have any advice?? (a connector above the manifold would be useful)

Also I wonder if I should have taken the egr valve off first as it's still attached, I've stopped for lunch as I'm knackered & may well do that to give a bit more room if it's possible.

Oh should have said - 2002 E320 cdi estate 250k miles
Rob

 

[St Ives Velo]

Update ... success it's out, eventually, the mystery wire went to the starter motor but was out of sight (or should I say my 74 yr old eyeballs) but rescued by a digital camera for a closer eyeball on the situation, surprising how much easier is when you know what you're aiming for even though it's out of view.
If you decide to do this don't forget to disconnect the battery!

It's all quite caked up so have left it overnight with some diesel poured onto the ports & will have a go at cleaning it up & freeing the swirl flaps & will add pictures later
Rob

 

[BlackC55]

If there is ANY play in those flaps the get a new manifold. Seen a few drop off and that's not good for the engine...

 

[St Ives Velo]

If there is ANY play in those flaps the get a new manifold. Seen a few drop off and that's not good for the engine...

Thanks for the advice, I have freed them up and scraped a load of gunk out and they do seem to be sound and ok as far as play goes but I will do a bit more cleaning & see how it looks, however the plastic socket on the actuating arm could be a closer fit on the ball joint, so I need to see if there's a replacement part available.

 

[St Ives Velo]

Received to find no discernible play in the swirl flaps after cleaning out the carbon build up ( it was a good thick coating), soaking it in diesel softened it up enough to easily scrape it out with a screwdriver and paint brush so no need for extreme cleaners. Will finish off with some brake cleaner or petrol.

EGR valve was stiff and sticky at first and took a bit of effort to move initially so left some diesel in top chamber for a while then worked it with a cramp until it freed up then plus gas then ptfe spray, it's now smooth and can be worked by hand but has a fairly strong spring.

 

[Smiley]

It's a very messy job isn't it. I did the same on an e46 320d BMW - I completely removed and blanked off the swirl flaps on that because they are prone to coming off......not sure if it is possible / recommended to do the same on the om613.

btw I can really recommend this Bilt Hamber Surfex HD product as the "nicest" degreaser to work with

Bilt Hamber Surfex HD APC Degreaser (1L, 5L & 25L)

Traffic Film is stubborn to remove but with Bilt Hamber Surfex HD it will truly shift the grease and grime from your car, a water based formulation makes it also safe to use all over your car's exterior.

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