Nicholas230e,

I am not certain of the spark plug gap at the moment, but as I recall if you buy the recommended spark plug listed on the last page of the owner's manual (called "Bedienungsanleitung" if you have the original German owner's manual) you do not need to gap them as they come correctly gapped. I have one of the 1984 230E's I imported "visiting" for the holidays (it belongs to my aunt) and I checked her manual. The plugs listed are:
-Beru 14 K-7D
-Bosch H 7 D
-Champion BN 9 Y

As far as the valves go, they are NOT equipped with hydraulic lifters, and must be adjusted regularly. The little cartoon on the upper structural crossmember and support for the radiator/lights should show the location and dimension of the gap, set cold and hot. The manual also has it listed cold on page 91, under "Ventilspiel" (meaning valve play), (kalter Motor) meaning cold engine, with the values of:

- 0.10 mm for the Einlass (inlet)
- 0.20 mm for the Auslass (exhaust)

If the cartoon is rubbed off or missing for some other reason, the measurement is made between the rocker arm pad and the top of the valve itself, not between the rocker arm and the camshaft lobe.

I hope this helps you, and good luck. Sounds like a nice car. The engine is very robust, as each one I imported (5 total 230E's) has run relatively trouble free for over 200,000 miles. Fuel pump relays seem to suffer in hot weather, which sounds like it won't be a problem for you. Jim

__________________
Own:
1986 Euro 190E 2.3-16 (291,000 miles),
1998 E300D TurboDiesel, 231,000 miles -purchased with 45,000,
1988 300E 5-speed 252,000 miles,
1983 240D 4-speed, purchased w/136,000, now with 222,000 miles.
2009 ML320CDI Bluetec, 89,000 miles

Owned:
1971 220D (250,000 miles plus, sold to father-in-law),
1975 240D (245,000 miles - died of body rot),
1991 350SD (176,560 miles, weakest Benz I have owned),
1999 C230 Sport (45,400 miles),
1982 240D (321,000 miles, put to sleep)