92 300D, W124 - Broken Ignition shut-off line

[Diesel Wannabe]

First off, I am a MB newbie who bought this car about a month ago. I really like it so far and while the engine, tranny and body seem very solid, I do have a few projects to get to. I've been reading threads for a couple of weeks and poking around the engine bay. I've checked with mbusa and they don't carry the manual for my car anymore. I got a CD from ebay.com and ordered a Haynes manual (hasn't arrived yet).

Here's what I want to fix:

1. Hard shift from 1-2 at partial acceleration
2. Glow plug light comes on after start, but not pre-start
3. All "idiot" lights are flaky, come on/stay on a lot
4. Test/change out all vacuum lines/components

After reading a lot of threads, I really like the wastgate actuator mod and want to do that. There is now a part supply issue so that mod is on hold. It did make me postpone the vacuum testing/replacement fix since I think I will be able to get rid of 2/3 of that once I do the actuator mod.

Anyway, last night I tracked down the cause of my tranny hard shift issue. The hose from the VSV was not connected and vacuum was connected to the wrong VSV port. Simple fix and the shift got much better.

Feeling good about that, I went on to the glow plug testing. I pulled the cap and connector from the glow plug relay and tested for continuity to ground for the 5 wires. I found that the middle wire on the 3-connection side was relatively open (200+ ohms versus .4-.5 for the other 4). Can anyone tell me which cylinder this is since my manual hasn't arrived yet (and I have to say that the CD is REALLY bad)?

While I was putting the cap back on the relay, my arm hit the small feed line to the ignition switch for injection shut-off and it snapped. It was really brittle and needed to be replaced anyway. I haven't started the car since - I assume that it won't shut off, right?

How tough is this to replace and can I get replacement lines of the proper colors for these hard lines or do people just use the white/clear? Do I tape the new line to the old and just pull it through the firewall or is there more to it than that... Sorry that to ask for help on what is probably such a trivial matter.

TIA

[sixto]

Go to www.startekinfo.com -> MB Workshop Resources -> Service Manual Library CD/DVD -> Model 124 Service Library for no cost on-line access to the FSM. It's a clunky interface. If you don't find something in Disc 1, start over and look in Disc 2. MB does a better job with factory training than many other manufacturers so the manual isn't a DIY guide for neophytes. Even factory techs say the FSM sucks

If you look closely at the connector, all connectors really, you'll see position numbers. In the case of the glow plug harness, the connector number corresponds to the cylinder. Cylinder 1 is closest to the radiator.

If all you snapped was the brown line downstream of the check valve, you can replace it with any similar line, or bridge the break with rubber vacuum hose. If you snapped the fitting off the check valve, you'll need a new brake booster vacuum line from the vacuum pump to the brake booster. It was about $60 the last time I got one. You can shut off the engine by firmly pushing the STOP lever on the injection pump.

You can white get plastic line by the meter/yard from the New Parts Catalog link at the top of the page. Colored and color coded line is ordered by part number and costs significantly more.

Sixto
87 300D

[Diesel Wannabe]

Thanks sixto. I will check out the online startekinfo manual.

I did just snap the vacuum line off about 6 inches from the T on the line going to the brake booster. I see 3' sections of line, but I don't think that will make it to the ignition switch and I'm not sure if there is a joint/connector in between. I will try and patch it in the mean time with some vacuum hose.

[sixto]

You can order continuous lengths. Call Phil.

Sixto
87 300D

[Diesel911]

If the Plastic Tubing broke in two get a section of Vacuum Hose and stic each end of the broke plastic tube into it.

Also there should be a Manual Shutoff lever somewhere on the Linkage or Fuel Injection Pump. It could be that the Tag is gone from it.