Last night I changed the spin-on fuel filter and also inspected the prefilter which was clean. I have a nearly full tank of fuel but the car again died twice on me this morning so I went ahead and ordered the relay unit which I should get sometime next week. By the way, the car seems to die more often when I have the blower on, indicating to me that it is indeed electrical-related. I'm keeping my fingers crossed that the relay is the problem and not something else. Thanks guys for all the help.

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2004 VW Jetta TDI (manual)

Past MB's: '96 E300D, '83 240D, '82 300D, '87 300D, '87 420SEL

Friend with same year car as yours was experiencing lots of gremlins too. Disconnected the alarm and all is well. I don't know how to disconnect, but it's probably a relay or a fuse. Worth a try until your part comes in.

This is a good idea. It never occured to me as my car does not have a factory alarm. Its worth a try.

Something else you should try before your new relay arrives, is to replace the fuses on top of the existing relay. There could be a minute hair-line crack, or contact oxidation.

Phil

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'95 E300 Diesel, 264,000 Miles. [Sold it]

I only inspected the fuses from the side and didn't notice anything abnormal. I have no idea how to disable the alarm but what I have found useful in the meantime is to keep the climate control off. In fact I have yet to see the engine die with the climate control off (knock on wood).

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2004 VW Jetta TDI (manual)

Past MB's: '96 E300D, '83 240D, '82 300D, '87 300D, '87 420SEL

I changed the relay last week and so far so good, even with the climate control on. So it looks like the relay was really the problem. Thanks again guys, you saved me a lot of troubles trying to diagnose this problem on my own.

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2004 VW Jetta TDI (manual)

Past MB's: '96 E300D, '83 240D, '82 300D, '87 300D, '87 420SEL

Do you happen to have the part number for the K40?

Matt, sorry for the delay, the part for a W210.020 1996-1997 E300 D is MB# 210 540 03 72.

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2004 VW Jetta TDI (manual)

Past MB's: '96 E300D, '83 240D, '82 300D, '87 300D, '87 420SEL

No problem. I did already find the number, on the module itself, of course.

After checking the price (125 from the local dealer) and deciding that it wasn't too expensive, I proceeded to crack it open. It appears to have a number of questionable solder joints. I tried to solder them, but my little 45W iron isn't enough to heat the large metal bars enough to do a proper job. The car still starts, so at least I didn't break anything, but I'm going to find a 100W+ gun and try again.

Just replaced that relay. $99 from the stealer. It's so easy to replace it's a joke.

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#dieselFLEET
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'97 E300
'99 E300

replace k40 mod ($100). Its in the mod compartment under hood in front of pass comp. Has fuses in it.

regarding the K40 relay and year model application.

K40 Relay
K40 Relay






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__________________
ASE Master Mechanic
asemastermechanic@juno.com

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Noise Vibration and Harshness (NVH).
Dynamometer.
Heat exchanger durability.
HV-A/C Climate Control.
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Technical Quality Auditor.
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