I badly need help on this dilemma.

Yesterday, my trusty 240D will not start. I traced the problem to a burnt smell on the glow plug relay beneath the steering wheel underdash with part no. 001 545 3532 with VDO brand. I have done my research and found out that this same relay is also made by stribel. This Relay can be replace with part no. 001545 2232.

The Glow plug on my car is the 18mm thread and 21mm wrench loop style. The loop glow plug is all in working order so my option right now is to find a replacement relay. However, i was shocked that the price for the new relay described above is $170. My next option then is to replaced the plug to the newer quick glow pencil type which cost around $100+ but I still have to purchase a newer style black glow plug relay which is much cheaper and modify the wiring.

Questions:

1. Can I use the newer style relay with the old loop style plug?

note: I have used on my other 1979 240D the old style under dash relay on the newer pencil type glow plugs with no issues. Is this correct? Am I pushing the relay to its limit?

2. Can the old relay be R&R? Do we have any guide or DIY page for this job?

3. How do I modify the old 7 pin plug to fit the newer style relay? any guides on doing this?

Any help from you guys would be greatly appreciated.

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1974 240D Sara
1977 300D Kristina
1979 300CD Claudia
1984 300SD Helga
1985 300D Pepper

Go get one at an auto salvage place. Most cars do not land up there because their glow plug relay has failed. If five dollars or so get a spare if possible as well. I have found in life as long as you have another replacement the part will not go bad again usually.

Thank you barry. old relays are hard to find nowadays.

I will have to convert it to the newer style relay.

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1974 240D Sara
1977 300D Kristina
1979 300CD Claudia
1984 300SD Helga
1985 300D Pepper

Switching to the new style GPs is about the best up grade you can make, you wouldn't regret it. You can use the old relay if you can find one at a bone yard but use an 80 amp strip fuse. You can also forget the relay and use a push button with a solenoid. Search for info on the 'push button" if you want to go that route, it works fine and no relay to ever again worry about

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1985 Euro 240D 5 spd 140K
1979 240D 5 spd, 40K on engine rebuild
1994 Dodge/Cummins, 5 spd, 121K
1964 Allice Chalmers D15 tractor
2014 Kubota L3800 tractor
1964 VW bug

"Lifes too short to drive a boring car"

In my location they are scarce now as well in the salvage yards. Much depends on where you live I guess.

You don't the newer style relay to put in the pencil plugs. You just need to put in the pencil style plugs with the big threads in. Make jumper wires that go from the fuse to the #4 cylinder then a wire to each consecutive GP. Then take the ground off. And your set.

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Copy that. Actually, I have already done this to my No.1 240D and I am very happy with the result.

I am planning on removing the old relay from no.1 240D so that I could use it to my other no.2 240D unit with the busted old style relay and with the old loop type glow plug.

I'm at a lost right now on how to proceed with the installation of the new type glow plug relay on no.1 240D considering that the wire harness is for the old 7 pin type relay under dash. I need a guide on doing this...

And Stevo, yes. I read the manual push type option for the glow plug and that is my last and final option I think....

Another question though, what kind of situations destroys the relay aside from its age and its time has already come...

ground? short circuit? defective glow plug?

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1974 240D Sara
1977 300D Kristina
1979 300CD Claudia
1984 300SD Helga
1985 300D Pepper

I had the same questions, re: installation of the new-style relay. Here's a page prepared by another forum member that helped me understand how to do it.

http://savingchase.com/diy-pages/glow-plug-enhancement/

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'Betsy the Getaway Car' : 1978 MB 240D, 582k
'The Mistress of the Sea' : 2001 Giant Boulder, 10.30k

I check the Link you have provided and it was very helpful. I know understood the color coding of the wires. however, the relay which came with my duraterm glow plugs was the newer left engine compartment located same with the 300SDs and had different terminal connections compared to the relay which the link above showed...

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1974 240D Sara
1977 300D Kristina
1979 300CD Claudia
1984 300SD Helga
1985 300D Pepper

Well back then the electronics were not the best in europe compared to most of the world. Or the individual european manufactured electronic components I judged to be substandard.

The strip fuse limits the total current to it's opening amperage, So the relay does not have to deal with a shorted plug that could produce too much current for the contacts. As the contacts oxidise and wear heat is created in that box. Voltage to the plugs drops a little as well.

Actually overall for the period the relay does last fairly well usually. These cars are very old and the start cycles on the relays are probably exceeding the original design expectations. One should have a spare relay or a jump wire in the trunk to bypass it if it fails on the road while away from home. Especially with the loop plugs as you may need the same jumper for an open loop plug.

I have tried to follow this story but now am confused.
The updated fat Pencil Glow Plugs can be bought as a kit with a Relay. It will not be a Realy that looks like the SD Ralay. That Relay is supposed to replace the stock one.

I am asumming the SD Relay is the type that in the US mounts on the Drivers Side Fender Well.
To use the SD Relay you need to get a wiring diagram (and the 2 connectors from a stock SD would also be helpful) to see where the origional SD Wires go and see it that is adaptable to your Ignition Switch and Glow Plug light.

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84 300D, 82 Volvo 244Gl Diesel

For what it's worth, I think a push button and a $30 solenoid/relay from the parts store is a better solution simply because your own mind and body become the timer and you can vary the time based on the conditions.
Get the pencil plugs. Bolt the relay in the engine compartment. Run 12 volts heavily fused to the relay, then on to the first plug, use jumper wires to connect the rest of the plugs and wire up a push button in the driver's compartment to activate the relay.
You could also used the same system with the existing loop plugs.

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1977 300d 70k--sold 08
1985 300TD 185k+
1984 307d 126k--sold 8/03
1985 409d 65k--sold 06
1984 300SD 315k--daughter's car
1979 300SD 122k--sold 2/11
1999 Fuso FG Expedition Camper
1993 GMC Sierra 6.5 TD 4x4
1982 Bluebird Wanderlodge CAT 3208--Sold 2/13

pm me your address, I can send you the relay from either of my parts cars. 80TD, or 78 240D
the 240 is a total rustbucket, so make me a list, and I'll send you whatever you want off it... I'm only taking the fender, and the cam

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John HAUL AWAY, OR CRUSHED CARS!!! HELP ME keep the cars out of the crusher! A/C Thread
"as I ride with my a/c on... I have fond memories of sweaty oily saturdays and spewing R12 into the air. THANKS for all you do!

My drivers:
1987 190D 2.5Turbo
1987 560SL convertible
1987 190D 2.5-5SPEED!!!

1987 300TD
2005 Dodge Sprinter 2500 158"WB
1994GMC 2500 6.5Turbo truck... I had to put the ladder somewhere!

Copy that. I will try to look for a wiring diagram. the SD relay is a lot cheaper brandnew compared to the original old relay. do you happen to know the part number of the relay that is supposed to replaced the old type aluminum tin cover of the pre 79 w123 240D?


Copy That! I will take you up on your Offer. Thank you very much!

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1974 240D Sara
1977 300D Kristina
1979 300CD Claudia
1984 300SD Helga
1985 300D Pepper

A Free Realy is best!
But, for others with the same issue the replacement Relays for the Origionals are in the $225-50 price range. This is what makes a complete Pencile Glow Plug with relay Kit up date especially attractive if you have a no good Relay to begin with.
But, you need to deal with Relay wiring issue

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84 300D, 82 Volvo 244Gl Diesel