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Raptelan's 1980 300SD

Started by Casey, 30 April 2011, 09:52 PM

Casey

At the risk of seeming a bit narcissistic, I thought I'd start a thread to document the work done on my car over time.  I really enjoy Squiggle Dog's thread and seeing the progress his car has made over time.  Plus, it will help me keep track of what all I've done, as when trying to add up everything I'd done on my last car, I kept remembering things I'd forgotten.  I intend on keeping this car forever, which means I'll be trying to get every little detail absolutely perfect.  It also means that I'll be making it into the car that *I* idealize...which will probably mean that I end up some changing out some of the options.

Fixed already:
* Windshield washers do not work. Hose was disconnected from motor.
* Fuel primer pump leaking diesel badly. Replaced!
* Injection fuel lines leaking diesel. All fuel lines replaced!
* Bad right hand motor mount. Replaced!
* Front door checks both broken, so doors do not stay open. Replaced!
* Vacuum tube broken at left rear of engine. Replaced!
* Removal of aftermarket Motorola car phone kit. Removed!
* Headlights (low beams) randomly shift between two different levels of brightness. New battery installed!
* Replace alternator, tightening bolt, and pulley
* Replace all belts
* Side trim gone from driver side, due to sideswipe collision. Replaced with trim from 1975 280SE
* Transmission doesn't always shift cleanly or engage when it should Replaced shifter bushings and added a quart of transmission fluid
* Driver inner door handle broken and workable only by pulling it forward. Replaced!
* New door, trunk, sunroof, windshield, rear window, and taillight seals. Replaced!
* Armrest has hole in the right side Got the plastic insert from a junk yard car
* Underhood lining is completely disintegrated and gone. Replaced with a new one
* Passenger side front inner door handle has cracked cast metal and needs replaced. Found a perfect one in a junk yard car
* Front brake pads needing replaced Done
* One fog lamp has broken lens. Replaced with a new OEM lens
* Left rear door check strap broken. Replaced
* All new fuses. Done, using copper/alloy fuses from MercedesSource
* Want Fog lamp guards. Ordered!

Things I need to fix:
* Odometer does not consistently work (works in the mornings sometimes, not the afternoons, has only counted maybe 1/4 of the miles driven since I bought the car).
* Climate control (currently ONLY heats, and cannot be turned off except by closing vents).
* Need new windshield gasket Resealed front windshield temporarily with silicon gel.
* A/C non-functional.
* Padding gone in back seat.
* Glow plug indicator light randomly flashes. Glow plugs all replaced, and verified they all glow in the engine, so wiring is good.  Light still flashes randomly.
* Vacuum leaks (automatic door locks do not work if car has been off for a couple minutes). Bought vacuum test kit to start tackling this...
* Seat height adjustment handles are both broken off.
* Passenger window goes only 1 inch down and then makes nasty grinding sound.
* Driver window regulator shattered.
* Power antenna does not go up very far. It now goes up most of the way - bottom two mast pieces are solidly stuck together.
* Grill is damaged.  Need at least new plastic and chrome lists. Chrome and plastic replaced.  Lists should arrive shortly.
* Small rust spot on back left.
* Paint rubbed off at right edge of trunk where lid was rubbing against body. Tried adjusting trunk but latching mechanism seems to be pulling it back over to the right.
* Minor damage to both bumpers - enough that they probably need replaced.
* Front license plate holder screw holes ripped out on top.
* Headlight doors need replaced.
* Taillight lenses need replaced.
* Rear driver-side carpet missing.
* Rubber drainage tubes in rear of engine compartment are shot and will be falling completely off any time now.
* Minor dents in bottom of rear driver-side door.
* Body damage in middle and next to mirror on driver door from sideswipe collision.
* Upper wraparound bumpers bent a bit due to sideswipe collision.
* Upper rear driver-side bumper mount pressed into fender from collision.
* Rear driver-side door does not open from outside, as side effect of collision.
* Air filter cover is rusty - needs stripped down and repainted.
* Gas cap does not lock.

Things on my wishlist:
* Zebrano wood shifter knob.
* Zebrano wood instrument cluster.
* Zebrano wood horn pad.
* Manual heater+A/C controls. Bought a 450SE to transplant this from
* Chrome wheel well moulding.
* Trailer hitch / tow bar.
* Badge bars on bumpers, or maybe 6.9 bumpers.
* Steel hubcaps from 280S or similar matching body paint color.
* Foot pedal control for windshield washer. Bought a 450SE to transplant this from
* Whitewall tires. Current tires have whitewalls facing inward, just need to reverse them!
* New speakers.
* Stereo with iPod controls, iPod wiring into glove box.
* GAHH leather seat skins, front and back.
* Wood+leather door panels, dash, center console, and other interior parts (I cry at the $$$ these and the seat skins would take, but remain determined).
* Mercedes 600 Limo horn!
* Black-painted grille plastic.
* Cibie CSR headlights.
* Rear fog light.
* Two-tone bamboo/tobacco interior.

Things I'm not sure about:
* Manual windows.
* Manual sunroof.
* Heated seats.
* Reclining rear seats.
* Euro bumpers; with euro badge bar.
* Rear headrests.
* Manual transmission.
* Horn ring turn signal control (from Mercedes Ponton).

Things I liked better about my W124 that I'd like to customize the W116 to have (note this is a short list):
* Hood that one person can easily open to 100% vertical.
* Power windows work without key in ignition, if a door is ajar.
* Rear headrests that recessed into the back dash at the touch of a button on the dash.
* Gas tank cover that opens sideways and stays that way without being held.
* Power passenger mirror.

This is certainly a volatile work-in-progress, expected to be added to and changed a little over time. :)



More pictures of the car

Replacement Parts I need:
* 1x 000 090 88 50 - Diesel Hand Primer Pump Ordered from CC/Installed!
* 1x 605 078 05 81 - Fabric Fuel Line (3 feet) Ordered from CC/Installed!
* 1x 617 070 03 81 - Vacuum Tube Ordered from CC/Installed!
* 1x 123 241 27 13 - Right-Hand Motor Mount Ordered from CC/Installed!
* 1x 007 154 45 02 - Alternator Installed by MB!
* 1x 000 155 84 18 - Fan Installed by MB!
* 1x 000 155 49 15 - Pulley Installed by MB!
* 1x 617 150 02 72 - Alternator Tightening Bolt Installed by MB!
* 1x 617 155 02 72 - Coupling Installed by MB!
* 1x 004 997 39 92 - Set of V-Belts Installed by MB!
* 1x 004 997 99 92 - V-Belt Installed by MB!
* 1x 004 997 93 92 - V-Belt Installed by MB!
* 2x 000 987 90 40 - Rubber Buffers for Fuel Tank Door Ordered from CC/Installed!
* 1x 116 760 09 61 - LH Inner Door Handle Ordered from CC/Installed!
* 1x 116 720 03 78 - Left Front Door Seal Ordered from CC/Installed!
* 1x 116 720 04 78 - Right Front Door Seal Ordered from CC/Installed!
* 1x 116 730 01 78 - Left Rear Door Seal Ordered from CC/Installed!
* 1x 116 730 02 78 - Right Rear Door Seal Ordered from CC/Installed!
* 2x 107 821 00 97 - Front Door Rubber Hose For Vacuum Tubing Ordered from CC/Installed!
* 2x 116 821 00 97 - Rear Door Rubber Hose For Vacuum Tubing Ordered from CC/Not Used!
* 1x 116 750 00 98 - Trunk Seal Ordered from CC!
* 1x 116 671 01 20 - Windshield Gasket Ordered from CC, but is currently NLA due to quality issues :(
* 1x 116 670 00 39 - Rear Window Seal Ordered from CC!
* 1x 108 782 00 98 - Front Sunroof Seal Ordered from CC!
* 1x 115 782 01 98 - Rear Sunroof Seal Ordered from CC!
* 2x 108 782 01 98 - Side Sunroof Seals Ordered from CC/Installed!
* 1x 116 826 01 58 - Left Tail Light Seal Ordered from CC/Installed!
* 1x 116 826 02 58 - Right Tail Light Seal Ordered from CC/Installed!
* 4x 116 725 00 65 - Door Window Sill Wipes Ordered from CC/Partially Installed!
* 20x 116 988 00 78 - Door Sill Holding Clips Ordered from CC/Partially Installed!
* 1x 116 698 01 98 - LH A-pillar Base Seal Ordered from CC!
* 1x 116 698 02 98 - LH A-pillar Base Seal Ordered from CC!
* 1x 116 760 10 61 - RH Inner Door Handle Ordered from CC!
* 5x 123 400 15 02 - 6" Steel-look Aluminum Hubcap Wheels Ordered from private seller!
* 1x 123 241 30 13 - Left-Hand Motor Mount Ordered from CC!
* 2x 123 240 10 48 - Engine Shock Ordered from CC!
* 2x 116 240 00 17 - Engine Shock Mounting Kit Ordered from CC!
* 1x 116 430 40 29 - Brake Booster Vacuum Hose + junctions Ordered from CC!
* 1x 617 584 00 21 - STOP sticker Ordered from CC!
* 1x 126 330 05 03 - LH Tie Rod Ordered from CC!
* 1x 126 330 06 03 - RH Tie Rod Ordered from CC!
* 1x 000 463 51 32 - Steering Column Shock Ordered from CC!
* 1x 001 420 99 20 - Front Brake Pads Ordered from CC!
* 1x 116 682 00 26 - Hood Pad Ordered from CC!
* 1x 116 888 00 23 - Grille Mesh Ordered from eBay!
* 1x 000 545 03 34 - Glow Plug Strip Fuse Swapped with brand new one from 300CD
* 1x 115 888 23 85 - Vertical Grille Bar Ordered from CC!
* 6x 116 888 01 85 - Horizontal Grille Bar Ordered from CC!
* 1x 115 880 03 88 - Blue Grille Emblem Ordered from CC!
* 1x 617 016 01 80 - Valve Cover Gasket Ordered from MercedesSource!
* 20x 123 400 00 27 - Hubcap clips for aluminum rims Ordered from CC!
* 1x 116 240 04 18 - Transmission Mount
* 2x 116 835 05 97 - Engine Bay Drain Hoses
* 1x 116 301 02 97 - red rubber boot for accelerator pedal - NLA :(
* 1x 116 826 03 89 - LH headlight door
* 1x 116 826 04 89 - RH headlight door
* 5x 115 401 03 24 - Stainless Steel Hubcaps

Big_Richard

fear not, post away.

I think posting on here about a days achievements working on the car is the icing on the cake as far as w116 ownership is concerned. Naturally experiencing the vehicle itself after the improvements comes first  8)


1980sdga

I have the same phone setup sans electronic box. Same exterior color as yours as well.

Who do you think drove these cars when new?  A cell phone was a big deal back then...

Casey

Quote from: 1980sdga on 01 May 2011, 01:48 AM
I have the same phone setup sans electronic box. Same exterior color as yours as well.
Really?  I wondered if it was a factory option.  It seems pretty well installed unless it's the source of the sketchy extra wires under the hood.  Are you sure you don't have the box?  It would be in the trunk, on top right, next to a compartental-plastic thing that I'm guessing is some bizarre part of the vacuum system.  It's just black and boring with a few wires coming to it, but says Motorola on it.

Quote
Who do you think drove these cars when new?  A cell phone was a big deal back then...
I wouldn't mind getting the thing working if possible/useful to do so.  I would prefer my cell phone to use an antenna external to the car.  However I'm afraid the technology is probably too old to be useful with current stuff.

Papalangi

Check out Kent Bergsma's site, http://www.mercedessource.com/

He has all the little bits you need and didn't know you could get such as copper alloy fuses to replace the aluminum ones you probably have now.

His leaking fuel shut off repair kit is $10.95, http://www.mercedessource.com/node/7677

I have a few of his repair books and they are well written and well made.

Michael
'83 300SD, I'm back!  It's the son's new car (12/2020)
1976 450SEL, 116.033  Sold it to buy a '97 Crown Vic.  Made sense at the time.
1971 250C, 114.023
1976 280C
1970 250/8

Casey

Quote from: Papalangi on 01 May 2011, 11:15 AM
Check out Kent Bergsma's site, http://www.mercedessource.com/

Thanks for the reference, I will!

Quote
He has all the little bits you need and didn't know you could get such as copper alloy fuses to replace the aluminum ones you probably have now.

Yeah, I replaced all my fuses with new ceramic/copper ones before.  I've got a few coppers now, but most are aluminum.  At least they all seem to be ceramic - many of my old ones in the previous car were plastic.

Quote
His leaking fuel shut off repair kit is $10.95, http://www.mercedessource.com/node/7677

My leak isn't in the fuel shut off, it's in the primer pump you use if you run the tank out of gas.  And something to do with the fuel lines on the valves...

Casey

This morning I noticed the front windshield seal was looking pretty bad.  Particularly in the center, where there was a large gap between both the rubber and the body, and the rubber and the chrome, which is bowed out a bit there.  I don't have a garage I can keep the car in, plus it may rain when I'm at work, so as a temporary solution, I used some clear silicon gel I had lying around to patch up the entire top strip of the windshield.  It's going to be at little bit before I can afford to think about new seals, let alone the labor of installing them.

When I went back out a bit ago to check the glow plug resistance, it was raining.  While the silicon gel was a bit of a hack job, it's nice to see it working:


1980sdga

My phone is a Motorola Dyna Tac 6000XL. I wonder if it was a dealer installed option?  My "black box" is gone from the trunk but the wires are still there.

Squiggle Dog

I look forward to your threads! It sounds like you are going to have a fantastic car by the time you are done with it. I know a guy who has a set of new complete bamboo leather seat skins for $400. I'm not a fan of leather, so I passed, but I can send you his info if you want.

You can move your hood to 100% vertical if you slide off the clips on each side of the hinges and push out the pins. You'll want to watch your windshield, though! And maybe make sure it doesn't suddenly close shut.
Stop paying for animal cruelty and slaughter. Go vegan! [url="https://challenge22.com/"]https://challenge22.com/[/url]

1967 W110 Universal Wagon, Euro, Turbo Diesel, Tail Fins, 4 Speed Manual Column Shift, A/C
1980 W116 300SD Turbo Diesel, DB479 Walnut Brown, Sunroof, Heated Seats, 350,000+

Casey

#9
Quote from: Squiggle Dog on 02 May 2011, 02:10 AM
I look forward to your threads! It sounds like you are going to have a fantastic car by the time you are done with it.

What is this "done" of which you speak?

QuoteI know a guy who has a set of new complete bamboo leather seat skins for $400. I'm not a fan of leather, so I passed, but I can send you his info if you want.

Nah, my interior is in pretty great shape for the time being, and if/when I go leather, I want to go all out (doing front and rear seats, headrests, armrest...), and maybe change the interior color to red or burgundy while I'm at it.  I've got some stock grants being cashed out sometime in the next few months, so when that happens, it's going to be fun time. :D

This is my GAHH wishlist - I'd still need to figure out door panels, etc. on my own:


QuoteYou can move your hood to 100% vertical if you slide off the clips on each side of the hinges and push out the pins. You'll want to watch your windshield, though! And maybe make sure it doesn't suddenly close shut.

I wonder what it would take to modify it to work like the W124.  You gently lower the hood just slightly while on one side to release a clip, then walk around to the other side, release the other clip, and it goes up to 100% vertical.  No worries about the windshield or it falling shut.  I'd pretty much always do this as it just made everything much easier, and is in my opinion one of the greatest Mercedes innovations.

jbrasile

Casey, when you get ready to do the interior let me know.

We represent GAHH in Brazil and get a pretty nice discount.

One suggestion though, keep the interior original. Probably the most important thing in these cars as far as originality and re-sale is the condition of the interior and how close to factory you can get when re-doing it, besides, MB-Tex is such a great material....

Just my 02..

Tks,

Joe


Casey

Quote from: jbrasile on 02 May 2011, 08:45 PM
Casey, when you get ready to do the interior let me know.

Okay.  It may end up being years though, if ever.  I dream of it, but don't know if I'd really want to put that much work into replacing what is already in good shape.  On the other hand perhaps the existing interior would have good market value to somebody.

QuoteOne suggestion though, keep the interior original. Probably the most important thing in these cars as far as originality and re-sale is the condition of the interior and how close to factory you can get when re-doing it, besides, MB-Tex is such a great material....

Well, I never plan to re-sell this vehicle - originality is something I intend to preserve in a lot of ways, but my goal is not restoration to original condition when there's something I feel can/should be better.  I also have a pretty strong preference for natural materials when possible.  I'd rather have something like Charlie's W116, though I don't have the money to do anything that amazing except perhaps bit by bit over quite a long time.

Casey

#12
Today new RH motor mount, fuel primer pump, and injector fuel line hose arrived.

I went at the primer pump first, since it's the worst leak and I figured it would be the easiest (my duct tape "solution" has, unsurprisingly, done next to nothing).  I was a little concerned about the replacement pump, as it's a totally different part than what's on the car, with a different thread pattern, and an adapter to fit one to the other.  It's a Bosch part, and it's native screw threads are steel.  But the adapter from that to what is apparently in my car is a piece of aluminum.  In addition to seeming cheap and comparably fragile, I worry that once this is screwed in, there will be no way to get it out, as the adapter piece has only a thin circle rim with no edges to grip onto.  A bit of a bummer.  But I figured it probably wasn't going to be the easiest thing to find a different replacement part right away, and I wanted to stop the fuel leak regardless of this concern.

I didn't have any wrench large enough to grip the bottom of the existing fuel pump.  It's also in rather a tight spot, with two other things attached right next to it, making it more difficult than I imagined.  I got a crescent wrench on it pretty good, but could not get it to budge - the wrench would turn but pump would not.  I got a pair of vice grips on the upper portion pretty good, but this, too, failed to turn the pump.  It just stayed firmly set while the vice grips cut into the steel a bit.  I guess I'll be picking up some Powerblaster soon and hoping that frees it up.




So then I decided to address the motor mount (the knocking/vibration of the engine has been pretty horrible).  I experimented a bunch and had success getting the engine jacked up and such, and confirmed that the existing mount is in sorry shape.  The new one is a totally different shape, so I'm guessing the one that's there is some aftermarket one.  I figured out I will need an allen wrench that I don't have to fit into the bolt that's below the motor arm, and I have doubt I'll be able to turn the bolt with such a simple tool.  There's not room to get anything else in there, though.  I tried getting the big bottom bolt loosened with a socket-mounted allen head.  It wouldn't budge.  I don't have a breaker bar but I'll probably buy and try that next, along with some Powerblaster.  I did try an air-powered ratchet that my landlord had, which does a slow turn with a lot of vibration - it wouldn't do a thing.  He also has a air-powered impact wrench.  I sort of worry I might tear my arm off with the thing.  I would have tried that, but it's a 1/2" drive and I couldn't find a 1/2" to 3/8" adapter.  So I might pick up an adapter soon too.

Update: Just got back from a late-night trip to Wal-Mart.  Have 1/2" to 3/8" socket adapter, and a can of Powerblaster.


Twice defeated, I decided to tempt fate by ripping off the brittle and leaky fuel injector hoses.  Darkness setting in, I got all of them finished with the aid of a flashlight.  Woo hoo!  Something productive done today, anyways.  See all the new lines that are light grey versus the old black:

OLD:


NEW:



That'll be a little less fuel leaking, anyways.  After I get the hand pump replaced, I plan on getting some degreaser and cleaning up the engine bay.  It's so dirty right now...


I also spoke with my insurance company again today.  They said they still have not managed to contact the other driver, and don't know when they might be able to get in touch with him.  I asked how long it might take, and they said it really doesn't matter, because they spoke with the independent witness, and feel that her recorded testimony proves that I was at fault because "she was independent and has nothing to gain".  Yeah, well she's a blatant liar too.  They said my passenger's witness was irrelevant, and they weren't even going to talk to him.  I asked how the other witness's testimony could possibly be valid given the photographic evidence I sent them.  They said that it was out of context, that they couldn't tell wihch lane the mark was in or which direction the camera was facing when it was taken.  I pointed out that there was a bit of sidewalk and a tree stump in the picture I sent, and they don't have either of those in the median, which could be confirmed by looking at a satellite image of the scene of the accident.  They said "oh uhh...well I guess we'll look at it again and consider that when we discuss the case when my boss is back in the office on Monday".  But he was being a real accusative jerk and saying it looked bad for me.

Here's the pictures of what happened for anybody who hasn't seen them:






So I guess I won't know anything until Monday at the earliest, but I'm going to be calling and bugging them again tomorrow and over the weekend.  I need to get a recording of them saying my passenger's testimony is irrelevant, as I'm not so sure that will be considered irrelevant in court, if it comes to that.  I don't know what it would cost to file against them - the damages are minor but I'm upset on principle that they're trying to blame me for failing to stay in my lane when I was clearly in my lane the entire time.  I believe it's their responsibility legally to investigate any and all evidence available and make a reasonable determination.  But I'll almost certainly just be repairing the damage at my own expense.

1980sdga

Too bad you couldn't get the pump and motor mounts replaced. I've been fighting with tools the past few days as well! It looks like you could get the primer pump off with a crows-foot wrench and a socket extension. (You say it was hard to get a wrench in there?) Sadly, you probably wouldn't ever need it again ...

  I'm running into a lot of 17MM's on this car so I got an extra 17MM (I only had one) and a 17MM gearwrench. I have a couple of the gearwrenches and they've come in really handy.

It's a PITA when you just can't find the tool for a job...

Casey

Quote from: 1980sdga on 05 May 2011, 10:35 PM
Too bad you couldn't get the pump and motor mounts replaced. I've been fighting with tools the past few days as well! It looks like you could get the primer pump off with a crows-foot wrench and a socket extension. (You say it was hard to get a wrench in there?) Sadly, you probably wouldn't ever need it again ...

I've never used croswfoot wrenches, so I don't know how well they would work.  The main issue is in getting the wrench securely onto the bolt, since there are two other connections RIGHT NEXT to it.  I think I may be able to disconnect the one in the picture above safely - I'm just not sure what it's purpose is or what the effect of messing it up and getting air into the system would be.  Crescent wrenches aren't really the most ideal for gripping things.  I think if I just had a plain straight wrench large enough (my largest size is 19mm which is too small), it would do the trick.

I'll have another go tomorrow, and buy a larger wrench if need be.