My 1979 240d was experiencing starting issues. There were days where the starter would just click and not start and after a few minutes of hitting the solenoid with a solid object it would start. The idea of getting stranded was bugging me so I replaced the starter with a remanufactured bosch unit. Now a new problem arose. A few days ago I went to start the car and its started just fine however there was an audible noise that was never there before. I opened the hood and found the starter still running and starting to smoke. I instantly turned off the ignition but to not avail. The starter would not turn off until I disconnected the positive battery cable. After the starter stopped I reconnected the battery and started it again and the starter did not stick. The next day same thing happened. It seems that the started only stays on after I try to start the engine for the first time. Since its a new (remanufactured) bosch starter can it be a faulty starter or do I have another issue. Where should I start looking?

Faulty Starter or not if it was smoking you need to exchange it while it is still under Warranty.

Before you install the next Starter take a really good look at the Flywheel Teeth to see if they are buggered up. Messed up teeth can Keep hold onto the Pinion Gear.

Locate the Wire that activates the Starter Solenoid so that if the Starter continues to run again you can disconnect the Wire. If it stops when you disconnect the Wire there must be something wrong in your Ignition Switch that is not cutting off the Voltage when you turn the key off.

This site has info on all kinds of autor repiar stuff. You have to pick out what does not apply to Diesels.
http://www.aa1car.com/index_alphabetical.htm

It has under Starter Keeps running: Damaged Pinion or Ring Gear, Faulty Plunger in Magnetic Switch (that is the Solenoid), Faulty Ingition Switch or control circuit and binding Ignition Key.

Also this particular Bosch Starter operates the same as an AC Delco/GM type starter and has an overrunning Clutch that the Starter Pinion Gear attaches to.

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84 300D, 82 Volvo 244Gl Diesel

I went to a local shop that specializes in Mercedes and spoke with an employee. He said to only purchase starters that were only remanufactured by Bosch themselves. Others tends to be faulty. So far the problem has not come back but if it does I will probably get a new starter. Thanks for the reply.

That is what a lot of the Members of this Forum have recommended.

I have owned my 1982 Volvo Diesel since 1992. It has a Bosch Starter and I had an issue with it one time. I took it apart and found nothing I could see wrong with it. Put it back on the Car and it worked; and have not had it off of the Car since then.
That is good reliability.
When I firs got the Car I had a Starter engagement issue that turned out to be burred Ring Gear Teeth that I filed down.
This last year once in a while I does not engage so I believe the Ring Gear is the cause; but, the Starter Motor itself seems strong.

Saw an add on eBay saying that the Mercedes Starter fit some Volvos so they must be similar.

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84 300D, 82 Volvo 244Gl Diesel

I just checked the E-Bay listing for a Mercedes diesel starter. Doesn`t show the 85 300D, CD etc... but the Federal one will use the same starter. the 85 Cali model uses a different starter. the solenoid is moved to the botom side to clear the Trap. not sure of the Bosch model/part number.

Two listings that were almost idential for 1973 - 1984 show the SR-61X and SR-67X

mercedes
240D 74 -83 L4 2.4L
300D, CD, SD. SDL, TD 68 - 84 L5 3.0L ( I think the SDL listed here is wrong)

Volvo Diesel
240 80 - 81 L6 2.4L

Audi 5000 81- 83 L5 2.0L


Charlie

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there were three HP ratings on the OM616...

1) Not much power
2) Even less power
3) Not nearly enough power!! 240D w/auto

Anyone that thinks a 240D is slow drives too fast.

80 240D Naturally Exasperated, 4-Spd 388k DD 150mph spedo 3:58 Diff

We are advised to NOT judge ALL Muslims by the actions of a few lunatics, but we are encouraged to judge ALL gun owners by the actions of a few lunatics. Funny how that works

I was told the 85 uses a different number of teeth on the flywheel due to the tach pickup, and as such, the starter on all 85's have only 9 teeth instead of the 11 on older models...

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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!

I have been kinda dissapointed with Bosch quality, most of their stuff now being make in China, or India. So, I tried to locate a heavy duty Denso starter. I have had good experience with Denso both in my Toyotas and in my 5.9 cummins. However its seems that Denso doesnt make starters for these good`ol diesels.

I too have heard a lot about Bosch stuff not being so good as it was. It is a shame because their original stuff - as the stuff that was fitted to my W123 when it was built - is bloody fantastic. I think it is so wonderfull I take these parts to bits just to see how nicely they are made!

"I want a doctor to take your picture so I can look at you from inside as well"

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1992 W201 190E 1.8 171,000 km - Daily driver
1981 W123 300D ~ 100,000 miles / 160,000 km - project car stripped to the bone
1965 Land Rover Series 2a Station Wagon CIS recovery therapy!
1961 Volvo PV544 Bare metal rat rod-ish thing

I'm here to chat about cars and to help others - I'm not here "to always be right" like an internet warrior



Don't leave that there - I'll take it to bits!

There is a couple of threads that have sources of Starter Parts.

So it is possible for someone to just fix what is wrong in their starter.

Don't know if they are still sold but in the Mercedes Parts list the bearing an bushing are even listed.

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84 300D, 82 Volvo 244Gl Diesel