I know. I know.

I would not usually undertake this insanity but its an '85 grey market TD under 200k and she is worth saving. Just bought her to restore to factory. Only driven about 5k miles with the kit installed (its an old used kit)

I need help in general, and also with one specific current issue.
I've been eyeing the system for a few days while also using the car as a daily driver. There is no WVO in the system (tank is clean).

Yesterday I went to start the car and the battery seemed drained, battery is ok, hook up a booster pack anyway, starter cranks and cranks and would almost turn over. Having the Greasecar computer connected (I had disconnected it on day one) made it seem much closer to turning over.

I am absolutely blaming the conversion kit for this. How do I fully disable it?


The big issue-

I want this system out. I don't know where to start. I don't know what the components of this kit even do, or what they're called or what I'm looking at.

I'm so used to my '82-'84s that any little difference in this euro '85 is making me more unsure.

I contacted greasecar about getting the mercedes install manual so I could reverse it, but no word yet.

ok, for the pictures, I'll start with in cabin electrical and move out:


this is the computer


this is what I found under the kneepanel, and what the computer is connecting to via firewire-three of the greasekit wires are easy to trace, two to the battery and one hooked up to fuse 5.







now to the engine bay:












I hate this. I love these cars because there's no stupid electronics

__________________
1985 300D Surfblau "Blueberry" 250K R.I.P
1984 300CD Manila Beige "The Banana" 238K R.I.P
1984 300TD Cypress Green "Olive" 390K (M.I.A.)
1982 300D Orient Red "Steak" 195K
1982 300D Mittelblau "Stilton" 172K- she's blue and she's crumbling-parting out!
1985300TD Surfblau 200k- "Pancake" Greymarket restoration project

I just looked. Their appear to be PDF files on the installation on the net. I did not get into them though. Indication was they also still may be in business.

Thank you, I've tried to get in touch with them (the computer version I have has a dvd for the install I think?) but no response so far....

Can't seem to find a PDF for mercedes though... anyone around here have one laying around?

__________________
1985 300D Surfblau "Blueberry" 250K R.I.P
1984 300CD Manila Beige "The Banana" 238K R.I.P
1984 300TD Cypress Green "Olive" 390K (M.I.A.)
1982 300D Orient Red "Steak" 195K
1982 300D Mittelblau "Stilton" 172K- she's blue and she's crumbling-parting out!
1985300TD Surfblau 200k- "Pancake" Greymarket restoration project

No offense, but before you blame the greasecar system for the issues, I would look at the general and overall condition of the engine. In your pictures I saw a lot of rust and dirt, and a lot of grease/signs of leaks. The picture of the injection pump and spin on fuel filter made me cringe. In general I saw many signs of maintenance neglect that could easily cause your issue. I would change the oil, all new filters (fuel and oil), new fuel tank strainer, and a fresh valve adjustment before I went any further. Just my.02 take it for what it is worth.

__________________
2012 Mercedes ML350 Bluetec 80K (hers)
2005 Corvette 55K (fun car)
2002 VW Jetta TDI 223K (mine)
1998 Volvo S70 T5 Turbo 180K (kids)
1994 Ford F150 4WD 245K (wood getter)
1983 Mercedes 300D 367K (diesel commuter)

Also, check your glow plugs for function. Pull them out and make sure they all glow white hot. Use a battery and jumper cables. Don’t just ohm them out.

Great point. I was gonna say to check glow system and replace glow plugs as well, but as usual, forgot......

__________________
2012 Mercedes ML350 Bluetec 80K (hers)
2005 Corvette 55K (fun car)
2002 VW Jetta TDI 223K (mine)
1998 Volvo S70 T5 Turbo 180K (kids)
1994 Ford F150 4WD 245K (wood getter)
1983 Mercedes 300D 367K (diesel commuter)

No offense taken! This is why I'm here.

She sat for several years before I nabbed her last week. I changed all filters, oil change, did a diesel purge, changed fuel filters again before driving 7 hours home and she's been running beautifully.

I'm just frustrated that it went from instant turnover (every time!) to this, it really just felt like a bad batt but now it feels like I'm not getting any power to the starter, or I killed it cranking.

Fuel tank strainer and valves I have not touched yet, thank you.

The engine bay needs a lot of elbow grease and swapping units from my parts car. I figured I'd get to that once I got the greasecar nonsense out.

Thank you!

__________________
1985 300D Surfblau "Blueberry" 250K R.I.P
1984 300CD Manila Beige "The Banana" 238K R.I.P
1984 300TD Cypress Green "Olive" 390K (M.I.A.)
1982 300D Orient Red "Steak" 195K
1982 300D Mittelblau "Stilton" 172K- she's blue and she's crumbling-parting out!
1985300TD Surfblau 200k- "Pancake" Greymarket restoration project

She's been starting strong, but I am going to check everything. this is going on the list, thank you!

__________________
1985 300D Surfblau "Blueberry" 250K R.I.P
1984 300CD Manila Beige "The Banana" 238K R.I.P
1984 300TD Cypress Green "Olive" 390K (M.I.A.)
1982 300D Orient Red "Steak" 195K
1982 300D Mittelblau "Stilton" 172K- she's blue and she's crumbling-parting out!
1985300TD Surfblau 200k- "Pancake" Greymarket restoration project

I'm lost on this thread.....

Observation: The alternator has NOTHING to do with starting the car. It charges the battery when the engine is running. All the statements about the alternator turning over is making me scratch my head. Are you talking about the starter motor?!

Question: Is the engine actually cranking (as in rotating) when you turn the key? You state that the "alternator cranks and cranks and would almost turn over." "Turning Over" refers to the engine rotating when the starter motor engages. Is the engine actually rotating? If so, it's "turning over". If it's slow, you have a weak battery or poor battery connections.

Start with the basics as mentioned above. See if the lift pump is moving fuel. If it isn't, try running from a temporary container, perhaps the tank strainer is clogged or there is a fuel shutoff solenoid from the greasecar kit that needs to hit the road.

Good lord, I am too exhausted to be allowed to type. Yes the starter, of course, after 12 years please believe I know the difference. For shame.

Going to move through the list and if not I've got a buddy to give it the old bang with a broomstick if needed.

__________________
1985 300D Surfblau "Blueberry" 250K R.I.P
1984 300CD Manila Beige "The Banana" 238K R.I.P
1984 300TD Cypress Green "Olive" 390K (M.I.A.)
1982 300D Orient Red "Steak" 195K
1982 300D Mittelblau "Stilton" 172K- she's blue and she's crumbling-parting out!
1985300TD Surfblau 200k- "Pancake" Greymarket restoration project

So is the starter failing to engage and rotate the engine?

Per this pic, you have air in the clear hard line from the lift pump to the fuel filter. It also looks too dark to be diesel. Since you car started and ran fine before, charge up the battery and concentrate on bleeding the veg and air out of the system.

__________________
85 300D turbo pristine w 157k when purchased 161K now
83 300 D turbo 297K runs great. SOLD!
83 240D 4 spd manual- parted out then junked

decent diagram of a system

Attached Thumbnails

 

Make sure the fuel tank breather isn't clogged by loosening your fuel cap and listening for suction. If you hear air woosh in, your tank has become a vacuum chamber and you won't get any fuel if the lift pump can't overcome it.
You may also want to check every rubber seal and hose from the tank to the lift pump, to the filter to the IP and back to the filter. Running WVO or bio can and will destroy all the rubber seals and you can be sucking in air this way or bleeding out fuel pressure at the top of the IP if the delivery valve seals are done. It's good practice to do anyway regardless what you run, WVO, bio, or even plain diesel.
Phil Forrest

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1972 220D "Trudy," named by a friend.

"The 220D sounds good... I suspect it is the only car that you need a calendar for, rather than a stopwatch, when doing acceleration tests."
Tom Abrahamsson

We have a winner!

So, solenoid stuck open at the 3 port in the grease system was keeping the flow open-no purge of the system with diesel at shutdown.

Then of course, I go to start it the next day and that cold WVO isn't going ANYWHERE.

I bled as much of the oil and air out as possible without the car running and blasted the IP and injectors with two hairdryers (with a 50 foot extension cord, on the street in Brooklyn).

Back in business and joyfully removing all traces of modification.

Thanks so much to everyone for the help, the issue mimicked several other problems so closely that it was a bit tricky to solve.

__________________
1985 300D Surfblau "Blueberry" 250K R.I.P
1984 300CD Manila Beige "The Banana" 238K R.I.P
1984 300TD Cypress Green "Olive" 390K (M.I.A.)
1982 300D Orient Red "Steak" 195K
1982 300D Mittelblau "Stilton" 172K- she's blue and she's crumbling-parting out!
1985300TD Surfblau 200k- "Pancake" Greymarket restoration project