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VegGWagen
Member
Date registered: Jul 2011
Location: Thousand oaks, ca
Vehicle(s): 96 G300DT
Posts: 16
| Re: My 96 G300TD needs help
inkblotz; It is on the intake side. Its the air/ fuel mix with EGR valve.
Luky; if you can find a couple website that would be great thx! |
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nielsa
Regular
Date registered: Dec 2009
Location: Norway
Vehicle(s): 290GD (461- 603A,IC), 463 G350TD (-->300TD,603A)
Posts: 59
| Re: My 96 G300TD needs help
The G300TD has become a very popular upgrade from the 460 series lateley in Norway. Prices on the aftermarket has been good basically following starting and running problems like yours. There are at least 5 of the "hardcore" G-owners who as done the upgrade the last year. Beautyful cars when they start and run. All five has done a total rehab of all o-rings and plastic fuel lines including o-rings on the pump and intake manifold. Some has blocked the EGR -valve too.
THis fixed their problems.
You can watch some of it here:
http://norskgwagen.com/index.php/forum/16-Medlemmenes-biler/5527-G3...
Good luck!
nielsa |
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Inkblotz
Expert
Date registered: Apr 2006
Location: Georgia
Vehicle(s): 90 300GD "Thundering Turtle II", w/ 603A turbo
Posts: 3186
| Re: My 96 G300TD needs help
Thanks for the clarification. Pierburg (the folks that make the diesels vacuum pumps) makes them part number:7.22331.55.0
For the US 606 turbo D sedans the part used is either: 6060980117 ; 6060900154
#140 in the pic
Edited by Inkblotz 4/25/2014 6:16 AM
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AlanMcR
Expert
Date registered: Apr 2006
Location: US, CA, Los Altos
Vehicle(s): G300DT E300DT 230SL
Posts: 3500
| RE: My 96 G300TD needs help
You need part number 137 with the integrated valve lift sensor. The 140 part won't work. BTW: It is the lift sensor that fails on these. There is a little sliding resistor inside the sensor that wears out. No way to fix that. ...Alan
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Inkblotz
Expert
Date registered: Apr 2006
Location: Georgia
Vehicle(s): 90 300GD "Thundering Turtle II", w/ 603A turbo
Posts: 3186
| Re: My 96 G300TD needs help
Alan have you tried that #140 system? I'm curious as to why it would not work. Are there different electrical connections to it? If as neilsa says that in europe they have simply blocked it off I would think attaching the #140 would be a nice replacement. Please school me on this. |
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AlanMcR
Expert
Date registered: Apr 2006
Location: US, CA, Los Altos
Vehicle(s): G300DT E300DT 230SL
Posts: 3500
| RE: My 96 G300TD needs help
The version of the EGR on both the S-class and G-class has an extra sensor on the valve. This goes into the engine computer. Without a valid signal the ECU drops into limp mode. I have designed a circuit that fools the ECU into thinking the EGR is working as commanded, but it isn't trivial. It includes active components and ties into five separate ECU lines. |
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Luky
Elite Veteran
Date registered: Apr 2006
Location: Bratislava, Slovakia, EU
Vehicle(s): 300GE LWB auto, E320CDI 4M, VW Polo Classic 1.6
Posts: 1062
| Re: My 96 G300TD needs help
So it took me a bit longer than I tought, but after a several calls to my dealer they told me the pt. nr. A6060900254 was replaced by pt. nr. A6060980017, that part is available for example here for 391 euro plus 65 euro shipping to the US
http://eshop.original-teile.de/index.php?force_sid=73893df5f131af24...
also it is available here
http://www.online-teile.com/mb/advanced_search_result.php?XTCsid=cb...
but the price is a bit higher and they don´t have the shipping costs to US ot their website.
EDIT
I also found the part is made by a company called PIERBURG (a large EGR valve manufacturer) and their pt. nr. is 7.22331.11.0 (722331110), so maybe You would be able to order it directly in the US from somebody who sells PIERBURG products.
Edited by Luky 4/28/2014 10:42 AM
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VegGWagen
Member
Date registered: Jul 2011
Location: Thousand oaks, ca
Vehicle(s): 96 G300DT
Posts: 16
| Re: My 96 G300TD needs help
Thanks for the info gentlemen, I appreciate it sooo much. Alan I think just going with a new egr lift sensor might be a better route for me. The thought of trying to hard wiring the bypass seems a little beyond me. I'll let you know how the search for the part goes.
to be continued |
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VegGWagen
Member
Date registered: Jul 2011
Location: Thousand oaks, ca
Vehicle(s): 96 G300DT
Posts: 16
| Re: My 96 G300TD needs help
update on repairs
So we ordered the EGR from Germany, (thanks Luky! for the link)
we just installed it and it has the SAME PROBLEM. symptom has not gone away.
so here's the list of repairs so far
EGR just replaced
wastegate rebuilt
MAP sensor
coolant and temp
all injectors
fuel lift pump
alternator
all vacuum lines
K40 relays
2 transducers?
all that's left is the ECU, any other suggestions? I'm at wit's end, do you think the ECU could be the source of the problem? |
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AlanMcR
Expert
Date registered: Apr 2006
Location: US, CA, Los Altos
Vehicle(s): G300DT E300DT 230SL
Posts: 3500
| RE: My 96 G300TD needs help
Sorry to hear of your continuing troubles. I went through a mini version of that recently. What are the current symptoms? What does the diagnostic computer complain about now?
Edited by AlanMcR 6/19/2014 4:31 PM
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Roly
Elite Veteran
Date registered: Apr 2006
Location: Australia
Vehicle(s): 1999 G500
Posts: 661
| Re: My 96 G300TD needs help
There are places that can run a test on the ECU to see whether there is a fault. I've used the link below recently and the guy was superb. He has a test rig which will simulate every condition of evey component and check output. Usual test fee is about £50 + shipping. There must be similar places in US. Certainly don't buy a new one 'till you tested yours. Many ECU components can be repaired too.
http://www.remmington.info/
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thebigblue
Date registered: Jan 2012
Location:
Vehicle(s):
| RE: My 96 G300TD needs help
Sorry I´m not able to give any hints,
but I love the Baja-rack and will try to manufacture one with a somewhat similar look, but made from aluminum tubing, - so could I persuade you to snap a close-up of the feet that attaches to the rain-gutter ?
Thx |
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VegGWagen
Member
Date registered: Jul 2011
Location: Thousand oaks, ca
Vehicle(s): 96 G300DT
Posts: 16
| Re: My 96 G300TD needs help
Thanks Roly, Ill look into that. There supposedly is a place here in California that might be able to do that. If not ill check that out.
Alan, same symptoms, at about 3000 rpm, as soon as load hits, the wastegate dumps wide open and stays open until the load goes away. if you disable the wastegate signal, then it will stay closed |
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AlanMcR
Expert
Date registered: Apr 2006
Location: US, CA, Los Altos
Vehicle(s): G300DT E300DT 230SL
Posts: 3500
| Re: My 96 G300TD needs help
No reported errors? I ran a 0-60 test (lousy youtube video here ). Might want to do the same as a comparison.
Does the manifold pressure actually drop? Is there a big power difference between letting the wastegate do it's thing and locking it closed? I know that sounds obvious, but that is a really small turbo and it may need to open up to avoid overspeed.
Edited by AlanMcR 6/20/2014 1:15 PM
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VegGWagen
Member
Date registered: Jul 2011
Location: Thousand oaks, ca
Vehicle(s): 96 G300DT
Posts: 16
| Re: My 96 G300TD needs help
It does. I think because the waste gate is being opened and not allowing pressure to build in manifold. It goes up when revving to 3k then then drops when waste gate is opened. |
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VegGWagen
Member
Date registered: Jul 2011
Location: Thousand oaks, ca
Vehicle(s): 96 G300DT
Posts: 16
| Re: My 96 G300TD needs help
on 0-60 what happens is it will accelerate normally until load hits at around 25 mph, 3k rpm then wastegate will open and will stay at 3k rpm and slowly gain speed on engine only on wide open wastegate extremely slowly. at that point its essentially acts like its naturally aspirated |
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AlanMcR
Expert
Date registered: Apr 2006
Location: US, CA, Los Altos
Vehicle(s): G300DT E300DT 230SL
Posts: 3500
| RE: My 96 G300TD needs help
No codes reported? This is crucial. Because the ECU is monitoring all the sensors for expected values. As a test of the diagnostic system try unplugging one sensor at a time and seeing that the ECU appropriately drops into limp mode and logs a fault. Similarly clamping the vacuum lines to the EGR and turbo (one at a time) should result in a fault. Actually, I'd start by clamping the turbo line.
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VegGWagen
Member
Date registered: Jul 2011
Location: Thousand oaks, ca
Vehicle(s): 96 G300DT
Posts: 16
| Re: My 96 G300TD needs help
When operated with no vacuum hose(clamped line) to waste gate, the car will rev all the way to redline with no problem, just a major lack off power ( just like an N/A diesel). Once the vacuum to the waste gate is plugged back in, symptom comes back and is the same. Sometimes, not all the time, when car is cold( below/at 40 below 80) the car will run to redline with boost no problem. When it hits normal running temp, same issue occurs again. Car wants to run full power past 3k rpm but with waste gate opens, it's like it hits a wall and slowly pulls past 3k rpm with the waste gate full open, the turbo singing and lack of power.
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