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Old 03-08-2009, 08:31 PM
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Join Date: May 2007
Location: Greensboro, NC
Posts: 117
1978 240D won't start

Folks,

I'm in a lurch. After servicing the injectors (nozzles replaced and pop-tested at an injector shop), the engine will not start. I've been following the fuel-pressure-heat-air formula, but I'm running out of leads. Here's the list of what works:

Fuel:
# Bled air from the hard lines until fuel emerged at each injector
# IP reset to 24* BTDC

Pressure:
# Battery is new (Group 49-R, replaced last week; started at 12.75 V, discharged down to 12.43 V, going on slow charger tomorrow)
# Valves adjusted 3,000 miles ago; chain stretch of 5* ATDC by camshaft tower method
# Starter motor works (engages when key is turned far right)

Heat:
# Glow plugs engage (relay is shot, so I've been removing the relay wire from the last plug and jumping the plugs straight from the battery for 30 seconds; voltage input at the plug on cylinder four is 10.6 V; all four plugs were replaced last month, and I measure voltage all the way down to cylinder one)

Air:
# I'm assuming the engine is receiving air; haven't replaced filter because the engine seemed to be running well enough with the old one

Even though I bled the hard lines, it still seems as if no fuel is reaching the engine: after cranking for two minutes (fifteen-second intervals), it won't catch. I don't even see unburnt fuel coming out of the exhaust, which is surprising since this car has always smoked profusely when it fails to start. What should I check next?
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'Betsy the Getaway Car' : 1978 MB 240D, 582k
'The Mistress of the Sea' : 2001 Giant Boulder, 10.30k
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