'77 240D - Mercedes-Benz Forum

 
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post #1 of 6 (permalink) Old 03-10-2014, 03:26 AM Thread Starter
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Post '77 240D

So I just bought a 1977 240D, originally a 300D but had a rebuilt 240 motor put in it. The motor has less than 30k, new clutch 3k ago, runs drives and shifts GREAT! However this thing is quite a basket case for a guy who doesn't know much about how to work on cars let alone an old mercedes that's hard to get information/parts/help on. Thing is I love this car and though I could easily trade it to someone for a working running car I want to fix it up and make it my daily driver as the motor will last me a long time!

These are the main things I need to do on it to get it to be able to be drive daily. And I will post pictures soon too. Also, these problems are written in order of importance. Antyhing you have to contribute will help me greatly!

-Glow plug relay: The mechanic i bought if from put a newer 80s model relay in it, I have to figure out how to wire it in, I'm guessing take all the wires through the firewall and manually wire it into the old glow plug wire housing somewhere under the dash by the drivetrain is what I've read? However the wiring on it is quite confusing to me, it's spliced into a plug on one part and what not. If you know how to locate this and what I need to do to wire it that would be great. The new pencil-shaped upgrade is already in place and wired into the relay thank GOD, just have to give power to and wire under dash the relay now.

-Heater: Currently not connect, though he SAYS the core is good and will work once I find out how to connect it back together. I believe him because everything he's told me about this car has turned out to be true. I just have no idea how to do this. It's all spaghetti wires through the firewall right now and totally cattiwompus.

-Fuel shut-off: Key doesn't turn it off. Have to put it into 4th gear and kill engine to shut off. Which SUCKS. I looked on dieselgiant and they want $198.00 for a new fuel shut off valve. So I really hope I can either figure out where mine is under the hood and make it work, or find one in pick n pull (already been there half a dozen times pulling parts off other mercedes for this car!!!)

-Random wiring stuff, for example the turn signals don't work right now, can't figure that out, there are random wires that aren't hooked up to anything under the hood like cruise control, a wire that goes from underneath the speed guage out to the motor that looks like a manual choke adjustment

Random other things like only two windows will roll down (power windows), don't know whether it's bad wiring or need new regulator motors, hood won't latch correctly even after getting a different latch from a 78 240 etc., etc.


I bought this car because I wanted to convert it to WVO and also just because I want to teach myself to work on cars and understand mechanics better so I know how to work on cars better when problems come up. However I am at the verge of giving up, I have a guy who wants to trade me straight up for a 87 Subaru GL wagon and it's tempting but I want to stick with this thing and see if I can figure it out.




This is the new relay, just plugged that big red cord to the battery and then to the starter solenoid, not sure where to go from there...







There's just spaghetti wires everywhere; vaccum lines, electrical, etc



1977 Mercedes 240D 191000 miles

Last edited by scoobychuck92; 03-13-2014 at 01:51 AM. Reason: to add photos
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post #2 of 6 (permalink) Old 03-10-2014, 10:31 AM
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Originally Posted by scoobychuck92 View Post
-Fuel shut-off: Key doesn't turn it off. Have to put it into 4th gear and kill engine to shut off. Which SUCKS. I looked on dieselgiant and they want $198.00 for a new fuel shut off valve. So I really hope I can either figure out where mine is under the hood and make it work, or find one in pick n pull (already been there half a dozen times pulling parts off other mercedes for this car!!!)
The fuel will also not shut off if you don't have vacuum going to the shutoff valve. You need to figure out if it is a vacuum leak first.

Currently: 1967 250 SL, 1963 220Sb, 1965 300SE Lang, 1971 280SE parts car, 1972 Alfa GTV, 1965 Alfa Duetto, 1993 BMW R100R
Past: 1971 250 C, 1985 300 TD, 1967 250 S, 1968 280 S,1981 300 D, 1982 280CE, 3 Facel Vegas, Borgward Isabella Coupe, Alfa 2600 Sprint, Volvo P1900 (yes), numerous less interesting Volvos, ...
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post #3 of 6 (permalink) Old 03-10-2014, 11:47 AM Thread Starter
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alright, do you know where to locate this thing?

I just ordered the chilton manual for this car so hopefully that will assist a lot in locating things
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post #4 of 6 (permalink) Old 03-10-2014, 03:38 PM
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No, I don't know. What I can tell you is that there is a lot of reading you can do about vacuum and locks and doors and A/C and heat and engine not shitting off and everything going wonky because of vacuum lines. Diesel Giant I think has some tutorials on it, I would start there. I definitely wound not assume that you need to replace something yet. Does your engine have a lever on the top of it with a worn-off sticker that says "STOP"? That's the stop lever for Mercedes diesels from this time period. It's because if you lose vacuum the engine won't shut off unless you press the stop lever, or in your case, pop the clutch in 4th gear.

Currently: 1967 250 SL, 1963 220Sb, 1965 300SE Lang, 1971 280SE parts car, 1972 Alfa GTV, 1965 Alfa Duetto, 1993 BMW R100R
Past: 1971 250 C, 1985 300 TD, 1967 250 S, 1968 280 S,1981 300 D, 1982 280CE, 3 Facel Vegas, Borgward Isabella Coupe, Alfa 2600 Sprint, Volvo P1900 (yes), numerous less interesting Volvos, ...
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post #5 of 6 (permalink) Old 03-10-2014, 04:09 PM
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Proceed to the W123 forum.

Felicita e un bicchiere di vino con un panino.
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post #6 of 6 (permalink) Old 03-13-2014, 01:55 AM Thread Starter
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So I added some photos, also this car has a major vacuum seal problem. There is nothing hooked up to the heater and I have no idea how to get the heater hooked up and there are a ton of vacuum lines that go to that thing. This is one of the things that seems to be really hard to find resources on. I read all of diesel giant's stuff, but it's more like hunting leaks, my problem is that nothing is even connected right now.

Does anyone know where I can get a shop manual for this car? I ordered the haynes one off amazon but it's taking forever, besides I don't know how specific it's going to be in helping me with this stuff...
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