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'86 W123 200, OM617 non-turbo, bastard 5-speed; '95 W202 C250 Diesel, OM605 non-turbo, 5-spd man
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4,313 Posts
Discussion Starter #41
Even though the rear seat is out along with the WIP rear shelf, I took Smokey to town for my bi-weekly lockdown shopping.
 

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1985 300 TD 1981 300 SD
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429 Posts
Treated the 85 to new injectors today, they checked between 1950 & 2000 psi on the tester before installation.


While I was there I also had a look at the pre-chambers which look fine though it's hard to tell from the pic I took of the #1 pre-chamber.

I also did a test on the glow plugs while the injectors were out which revealed one which was starting to fail, of course it had to be # 5 which made it a bit harder to replace due to the oil filter housing. ( no pic)
 

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W123 300CD, W123 300TD, W202 C250D Turbo
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212 Posts
Repaired leaking brakeline on the master cylinder - cracked as it had been bent flat by a previous owner and I tried to gently bring it back into position. Took 5mm off the line and made new bubble flare end. Installed A-OK. Changed the fluid and power bled the brakes while I was at it. Car now has a great brake pedal and good stopping.
 

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1983 W123 200T
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172 Posts
Resealed SLS pump and the leak has stopped. I think that replacing the o ring on the pump mounting flange helped also to stop engine oil leaking.
 

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1982 300CD
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5,161 Posts
I made some custom speaker boxes for the front doors.
I modified the map pockets using plywood and MDF, then stretched fleece over it and soaked it in resin.
Then I applied some body filler and sanded it relatively smooth.
Finally, I used Flex Seal to give it a black rubbery texture.
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'86 W123 200, OM617 non-turbo, bastard 5-speed; '95 W202 C250 Diesel, OM605 non-turbo, 5-spd man
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4,313 Posts
Discussion Starter #46
I discovered some new noises today while driving. One sounds random, like a loose component; one sounds rhythmic, and depends on the driving speed; both come from the rear left. I believe the rhythmic sound may be CV joints...
 

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W123 300CD, W123 300TD, W202 C250D Turbo
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212 Posts
Alternator on the wagon failed. Put one from a W126 420SEL in (75amp, a lot larger than the 55amp stock job) - 13.4v at idle, lights on high beam, fan on full, AC on.
 

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1987 560 SEC
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21 Posts
Well since I bought my first W123 in January...the list so far.

Removed all non OEM equipment installed including associated wiring.

Re-taped all “quick pinch” wire splice cuts in wiring found

Installed new radio w/ USB MP3 reader connected to Boston
Acoustics 3.5” drivers in front dash left over from PO.

Clean and lube sunroof tracks

New radio antenna.

Fixed high beam / fog lamp issue

Required state Inspection and registration

Removed rear parcel shelf board as was in bad shape,
hoping to replace with something a bit more substantial
with 2 spots for some nice rear speakers.

Added pool noodle foam under driver seat to eliminate sag

Installed LED fog lamp bulbs

Replaced front driver side window regulator with a
manually operated one.

5 New tires

New ignition key cylinder

Removing unneeded vacuum system lines and
components from the engine bay.

Undergoing process of converting AutoClimate system to
a RNE manual climate system as key components of the
AutoClimate system were missing.

First engine valve adjustment.






 

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'86 W123 200, OM617 non-turbo, bastard 5-speed; '95 W202 C250 Diesel, OM605 non-turbo, 5-spd man
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4,313 Posts
Discussion Starter #50
I finished the left speaker grille's press tool, and tried to press the grille. It didn't work.

I am now going to finish the speaker shelf without the grilles for now, while I figure out how to from the drilled mesh to make the grilles. Clearly YouTube lied to me...
 

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Registered
'86 W123 200, OM617 non-turbo, bastard 5-speed; '95 W202 C250 Diesel, OM605 non-turbo, 5-spd man
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4,313 Posts
Discussion Starter #51
Sadly, I didn't get to finish the speaker shelf as I had intended. But I have come really close!

I used news paper to make flat patterns of the carpet to plan the draping of the shelf.
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Happy that I could drape the shelf with three flat patterns, I then proceeded to cut and fit those flat patterns.

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The excess I have left will be fit around the edges as needed, or left to cover areas of the shelf that were previously left bare by mistake. The front lip will also be folded under the rear bench to help reduce the rattling of the shelf by those powerful 8-inchers. This whole thing will be ready to reinstall, albeit without the aluminium grilles, this coming Saturday.
 

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'86 W123 200, OM617 non-turbo, bastard 5-speed; '95 W202 C250 Diesel, OM605 non-turbo, 5-spd man
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4,313 Posts
Discussion Starter #52
Well, I could not be happier or more impressed with the improvement in sound quality!. No rattles, no resonance, just clean warm bass.

I will give the mesh grilles another try this coming weekend. I've had a rethink in my approach to forming the metal mesh.
 

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W123 300CD, W123 300TD, W202 C250D Turbo
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212 Posts
Changed gear selector bushes in the shifter and underneath on both sides of the lever. Shifter no longer vaguely selects a gear, all aligned to the position on the shifter, snap, sap snap as you select your gear. Also replaced night light with BA7S 2W globe.
 

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1982 300D Turbodiesel (US Spec)
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191 Posts
Got a new battery. The old one was killed by the glow plug relay.
 

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Premium Member
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64,838 Posts
Replaced broken bracket and dampers that hold air filter along with a craked breather hose.
 

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'86 W123 200, OM617 non-turbo, bastard 5-speed; '95 W202 C250 Diesel, OM605 non-turbo, 5-spd man
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4,313 Posts
Discussion Starter #56
Well, it was almost perfect. Almost.

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At least now I know that my method and tools work. Now I just have to plan the split lines better. Fortunately, this was the worst of three sheets of drilled mesh; I can make the final parts from the two remaining sheets.
 

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1985 300CD, 1985.5 Porsche 944, 1969 Triumph TR6, 1998 Land Rover Discovery I, 1992 Volvo 240
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1,394 Posts
Powder coated some vintage BBS Wheels to match the grey blue of my 1978 280E.
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1985 300CD, 1985.5 Porsche 944, 1969 Triumph TR6, 1998 Land Rover Discovery I, 1992 Volvo 240
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1,394 Posts
Same car got new carpets. They really make a big difference cleaning up an interior.


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1982 300D Turbodiesel (US Spec)
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191 Posts
Overhauled the brake system with a lot of help from my dad:

  • Resurfaced brake disc
  • New master cylinder
  • Resealed all calipers
  • New pads
  • New hoses
  • Repainted the brake booster
  • Adjusted the parking brake
 

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1985 300 TD 1981 300 SD
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429 Posts
Been driving the 85 daily for the last few months so today I checked the valve lash, only one exhaust valve needed a slight adjustment then proceeded to clay bar and wax the roof. I'll do the rest of the car during the week as the next couple days have rain in the forecast.
 
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