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| VegGWagen Member Date registered: Jul 2011 Location: Thousand oaks, ca Vehicle(s): 96 G300DT Posts: 16 | My 96 G300TD needs help Hello P3 community, A year ago I purchased an amazing 1996 G300TD on ebay, the car has been great other than some things that i've had a mechanic start repairing. First set of repairs were following All front suspension components/links Axle seals in front Both front wheel bearings Oil, oil filter, air filter 4wheel alignment a/c dryer with sensors after i began to address some of the problems that i began to experience as i drove the car: -whistling under boost -Stubble at idle, low speed engine shake -Sudden Loss of power at low speed and partial load cruising, apply more throttle then it makes power again No power past 3500 rpm, engine is still revving (symptom of no boost), holds gear and shifts late under this condition, but will shift immediately with light lift of throttle Has full power in full rev range when engine is cold (not operating temp), when it reaches full operating temp then no power past 3500 rpm occurs (problem listed above) car also has shown signs of no power at cold operating temp So first set of repairs were: Alternator Radiator EGR Valve Cleaned waste gate Exhaust manifold gasket second All 6 injectors, seals, return lines Water valve behind cylinder head under intake manifold Waste gate switchover valve 9 (vacuum) MAP sensor Transmission conductor plate Rebuilt transmission valve body All intake manifold gaskets, vacuum hoses/lines Battery was changed to 12V (previously was 10V) Sunroof seal Sunroof cable shroud Fog lamp wiring Items being tested/already tested: TPS sensor (currently being tested) Transmission line pressure (currently being tested) Vacuum operation of waste gate(tested) Output voltage of charging system (fluctuates quite a bit from 9v-13v, hence replacement of battery because it was not correct battery) so after all that i'm still experiencing: Sudden Loss of power at low speed and partial load cruising, apply more throttle then it makes power again No power past 3500 rpm, engine is still revving (symptom of no boost), holds gear and shifts late under this condition, but will shift immediately with light lift of throttle Has full power in full rev range when engine is cold (not operating temp), when it reaches full operating temp then no power past 3500 rpm occurs (problem listed above) the car also has shown signs of no power at cold operating temp occasionally Is there something that we may be missing? Thanks for any thoughts or insight, this has been driving me crazy trying to figure it out btw pics on their way (gwagen.jpg) Attachments ----------------  gwagen.jpg (336KB - 1 downloads) | |
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| AlanMcR Expert Date registered: Apr 2006 Location: US, CA, Los Altos Vehicle(s): G300DT E300DT 230SL Posts: 3500  | ||
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| jnicol Elite Veteran Date registered: May 2008 Location: Cranbrook, B.C. Canada Vehicle(s): 91 300GD, 911 (993), Dodge Durango, Subaru rally Posts: 680  | ||
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| DRT-DAN Member Date registered: Aug 2011 Location: Storrs Mansfield CT Vehicle(s): 1994 G320 VIN# WDB46323117096453 and a 1982 300SD Posts: 43  | ||
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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 What about the pressure control flap vacuum transducer which operates the manifold pressure control flap to regulate manifold pressure. http://www.youtube.com/watch?v=c31dgf8x2Wk From another site The vacuum supply to vacuum transducers must be checked. Below is the vacuum diagram for EGR and boost control. At the VAC end of the transducers- 700mbar of vacuum must be reached very fast, and stay that much always. Very often the non-return valve which supplies vacuum from brake booster gets dirty and sticks. A cleaning of the valve with WD40 might help if you find that the vacuum is not good. Another cause might be lying in the voltage supply. Both transducers recieve voltage from the fuse 2 in the relay module. It is located in the control unit box under the bonnet. Very often these relays have cold solder joints inside, and might be causing intermittent voltage interrupts. I suggest to disassmble the relay module and resolder the electrical joints there. Edited by Inkblotz 12/4/2013 7:34 AM (2009-09-24_160828_G300Dvac.JPG) Attachments ---------------- 2009-09-24_160828_G300Dvac.JPG (91KB - 1 downloads) | |
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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 Mark (Inkblotz), that valve doesn't exist on the turbo version, though similar vacuum modulators operate the EGR and Turbo. EM-G, First, welcome to the forum, it would be great if you could update your location in your profile. Most likely you are a victim of the lousy fuel system designed into this model. As a first test, shine a flashlight through the lines shown in the picture below. Have someone else rev the engine and see if bubbles are seen in any of the lines. Even with brand new fuel system parts, I can almost guarantee that you will see bubbles at higher revs. These are gasses pulled out of the fuel by fuel pump cavitation. It is a defect of the fuel system design. If you have any restrictions in the lines the problem gets progressively worse.(G300FuelLines.jpg) Attachments ---------------- G300FuelLines.jpg (206KB - 2 downloads) | |
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| VegGWagen Member Date registered: Jul 2011 Location: Thousand oaks, ca Vehicle(s): 96 G300DT Posts: 16 | ||
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| AlanMcR Expert Date registered: Apr 2006 Location: US, CA, Los Altos Vehicle(s): G300DT E300DT 230SL Posts: 3500 | ||
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| VegGWagen Member Date registered: Jul 2011 Location: Thousand oaks, ca Vehicle(s): 96 G300DT Posts: 16 | ||
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| nielsa Regular Date registered: Dec 2009 Location: Norway Vehicle(s): 290GD (461- 603A,IC), 463 G350TD (-->300TD,603A) Posts: 59  | ||
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| Inkblotz Expert Date registered: Apr 2006 Location: Georgia Vehicle(s): 90 300GD "Thundering Turtle II", w/ 603A turbo Posts: 3186 | ||
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| AlanMcR Expert Date registered: Apr 2006 Location: US, CA, Los Altos Vehicle(s): G300DT E300DT 230SL Posts: 3500 | ||
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| VegGWagen Member Date registered: Jul 2011 Location: Thousand oaks, ca Vehicle(s): 96 G300DT Posts: 16 | ||
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| Inkblotz Expert Date registered: Apr 2006 Location: Georgia Vehicle(s): 90 300GD "Thundering Turtle II", w/ 603A turbo Posts: 3186 | ||
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| Suppatime Member Date registered: Aug 2012 Location: Vehicle(s): 1980 300GD OM606 / 717.4xx Custom, 2003 C32 AMG Posts: 35 | ||
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| VegGWagen Member Date registered: Jul 2011 Location: Thousand oaks, ca Vehicle(s): 96 G300DT Posts: 16 | ||
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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  | ||
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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 VegGWagen - 4/24/2014 2:40 AM Ok here we go. The truck has been worked on for the past 3-4 months with no resolution yet. We now think it's the EGR because it wasn't repaired it was only cleaned out. I think with carb cleaner. So now we've been trying to either get a new EGR or a bypass. We've been scouring the entire WORLD looking for a new EGR and it looks like we may have found e part in Russia. The problem now is MBUSA seems VERY resistant to help us because supposedly they really. Don't want to help out gray market owners like us. So they don't want to go thru the trouble to get the part. So here's the part where I ask for a favor. Is there anyone outside of the US willing to order the part for me or see if they can get the part for me? I would be willing to send you the money for the part Nd shipping and a fee for your time and trouble. The updated part number I was given is 6060900254 Is this the part you are looking for? Does it look like this configuration? Here are the various models: E 300 DIESEL USA 96-97, E 300 DIESEL 95-95, E 300 DIESEL 96-97, E 300 DIESEL USA 95-95, E 300 TURBODIESEL 98-99, E 300 TURBODIESEL USA 98-99 And here is the part number for the same EGR valve: 0021402960 RE the updated part number: I would not necessarily go with the updated part. There may be some old stock out there that will work perfectly. Mark Edited by Inkblotz 4/24/2014 6:41 AM (Screen shot 2014-04-24 at 6.16.01 AM.png) Attachments ---------------- Screen shot 2014-04-24 at 6.16.01 AM.png (38KB - 0 downloads) | |
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