i made one more discovery. The flap that recirculates the exhaust to fresh air did move. It only moves once i start revving the engine. IT appears that it actually feeds the engine exhuast when the motor is reved up.

How can I reverse that?

What would happen if i just cut the flaps off? Would that solve my problems.

Be careful which flaps you remove!

1. The EGR valve can be blocked in your model without throwing any codes or otherwise causing problems. Simply make a replacement metal gasket to fit between the EGR valve and the air intake pipe. Make the gasket "solid," that is, no central hole. No more dirty exhaust in the intake! Leave everything else as it is, car looks stock, we won't tell.

2. The "throttle" flap just before the EGR valve can be removed. Its purpose seems to be to create a partial vacuum in the intake manifold and thus help suck more exhaust in through the EGR valve. Take that assembly off the car, remove two Phillips screws and the flap will slip out. Put the car back together, leave everything else as it is, car looks stock, we won't tell.

3. The flap in the crossover pipe and the flap in the intake manifold are there to "tune" the apparent length of the intake so the engine works better at various RPMs. You need to make sure those flaps are cleaned of the EGR soot and that they work properly but do not permanently remove them.

Jeremy

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"Buster" in the '95

Our all-Diesel family
1996 E300D (W210) . .338,000 miles Wife's car
2005 E320 CDI . . 113,000 miles My car
Santa Rosa population 176,762 (2022)
Total. . . . . . . . . . . . 627,762
"Oh lord won't you buy me a Mercedes Benz."
-- Janis Joplin, October 1, 1970

remove the rubber air intake pipe and check whats going on with that flapper. IMO just get rid of it - there are bigger fish to fry.

The ACC fans have fuses which are in the relays - the relays are in the fuse panel, check them - for a quick test - remove the two pin plug near the upper radiator hose on the cylinder head, the fans should run full speed. If not check the fuses and the wiring at the resistor - it burns off so neither speeds work.

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2012 BMW X5 (Beef + Granite suspension model)

1995 E300D - The original humming machine (consumed by Flood 2017)
2000 E320 - The evolution (consumed by flood 2017)