1990 240dl 1-1-3 error codes and idle problems

[durk80]

So, I am in the process of replacing the flame trap, and I discovered a cracked intake manifold gasket. Not sure if it was original, but it was made of a brittle red fiberous material.

I sent out the injectors as well as the cold start injector to get cleaned to Injector RX in Houston, Texas. I chose them because their service was reasonable and fair. The total was $78 with shipping included for four injectors cleaned, plus he didn't charge me for cleaning and testing the faulty cold start injector. Which, was probably also contributing to the rich burn if it was leaking fuel.

The coolant temp sensor and gauge sensor were also replaced while I was in there.

The rpm sensor was also replaced, because the cable to the old one was completely frayed and in quite bad shape.

The oil trap was surprisingly clean, however the EGR valve was completely gunked up, and the pipe leading from the valve to the exhaust manifold had several hairline cracks, probably which helped contribute to the rich mixture.

EGR parts are hard to find, so I put some high heat epoxy putty around the cracks. Once the epoxy was applied, I quickly wrapped some fiberglass cloth around the pipe to bond with the resin. Lastly, I covered the fiberglass with a silicone tape. This step was probably overkill, but I did not want have to take everything apart again just to get to that pesky pipe.

Speaking of the exhaust manifold, I decided to replace the gaskets. It was a good thing I did too. I found one that was cracked and disintegrated when removing from the engine. And the O2 sensor down pipe, when removed, was completely ensconced with a heavy cap of carbon soot. This was replaced as well.

Of course while everything was disassembled, the throttle body, intake manifold, and idle air control valve were cleaned too.

I sure hope that these repairs will fix the rich mixture condition once I get everything back together!

I'll keep everyone updated of whether or not it was a success or another challenge to solve.

Andy