Oh great!!! I thought people just skipped over my thread. Lol. There is lots more to come. After the oil cooler lines, oil filtering gasket, power steering hose and cigar hose goes on next week the exhaust manifold and turbocharger will be pulled apart for some refreshening. Well let me stop before I give it all away, but Id like to say I have bigs plans for this thing.

Good luck with your car!

Looks like cadmium plating to me

I think I am the only one who didn't have to use a pump or extension to refill my diffs. I simply got the long skinny jug, with the tip on it....and was able to fill them all the way up..

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Might have to try this next time to avoid this hassle.

Order left and right headlight doors and a rear differential mount since I have the old one off already.... At this point I am really ready to get it back together.

I for one have followed this thread, and must complement you on your progress. Your thread has given me encourgement to start looking for a new project, or parking my DD 300D for the winter and doing about 25% of what you have done so far. I should be so lucky to get 25% of that done through one winter.

I am in the same spot. I am getting some things done but not nearly as much as I wanna do by the end...

BTW the wedding date has been moved up a whole year, so now I have even less time.

Question: Im putting the the door panels back on today. I deep cleaned them and lubed the window regulator. Do I have to replace that plastic that was in the door? Whats its purpose?

With over 2600 views more than a few here are following it, or the future missus is checking up on your your progress quite often.

The purpose of the film is twofold; to keep the water off the door panel, and also to help keep unheated air out of the car. IE, it's a seal.

Nice! Thanks for the help. I didn't know what kind of plastic to use so I went to Lowes and used the free car liner they have. Lol. Hahaaaa.


Today I didn't do much but I did get the door panels cleaned up with new clips and back on. Now for the 2 rear doors. More to come Saturday.






Question: I have the rear diff mount off and the bolts off the diff but the cover still isn't coming off... Is it ok to take a crow bar to it? Or is there a better solution?

Dead-blow hammer works well; if you don't have one of those, how about whacking it with a chunk of wood?

There is a half round cutout (on the side?) where you can put a pry bar or large screwdriver to pry off the cover. I believe it is made for that purpose.

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All Diesel Fleet
1985 R107 300SLD TURBODIESEL
2005 E320 CDI (daily)

LOTS of parts for sale!


EGR block kit
http://www.peachparts.com/shopforum/diesel-discussion/355250-sale-egr-delete-block-off-plate-kit.html

1985 CA emissions 617 owners- You Need This!
Sanden style A/C Compressor Mounting Kit for your 616/ 617 For Sale + Install Inst.

Sanden Instalation Guide (post 11):
http://www.peachparts.com/shopforum/diesel-discussion/367883-sanden-retrofit-installation-guide.html

Another great thing to use for the vapor barrier is the $1 shower curtains....perfect thickness and you can chose a great color!

The door panels are looking pretty wrinkle....you should pull back the vinyl and redo the foam.

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Thanks guys! A combination of both works. That seal was pretty solid. I wonder if it needs to dry overnight when I go to put the over back on....


Now that is a good idea. After everything gets back together and I can finally enjoy driving her again I will definitely hit those small details.


Update: It took me 2.5 hours to get the oil filter housing off! I felt like shooting myself!! Now that I have it out, I am going to throw it in the parts washer for a couple of hours at work tomorrow.

a thin but even coating of black RTV (I used a putty knife to coat the entire sealing surface) installed fresh. I tightened the bolts untill a tiny bit of squeeze-out was visible around the edges then snugged them the next day for a leak-free seal

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1991 300D