The shopping has started. Several bits for a good service are on order. And I'm off to see a 717.412 in a bit...

Ahh, that explains your first post's comments about "top" gear being 4th. Every manual 201 I've seen has the 5 speed. Is the tranny in yours a 4 speed or did 5th take a poo?

Most of the 5 speed transmissions are ruined due to people not understanding the proper use of the "over-drive" 5th gear. Drivers try to lug them around town in 5th gear and burn the bearings out of them due to inadequate oiling at the low rpm range.

Yep I've got a genuine 4 speed - even the knob doesn't have 5 alive stamped on it.

It also explains my spreadsheet calculations in post #4

The 4 speed gearbox and differential combination has a slightly longer legged differential 3.46 instead of the 3.64 that was coupled with the 5 speed. I was just checking that I'd be able to get up all of the hills they've got here in Holland if I decide to be lazy and leave the "4 speed diff" in place.

So drum roll for new (transmission) project =>

http://www.peachparts.com/shopforum/...1&d=1373647688

Can anyone help to name the parts I don't know?
 

Orientation 101 for a new car

Some easy ones first

http://www.peachparts.com/shopforum/...1&d=1373657919

http://www.peachparts.com/shopforum/...1&d=1373657919

http://www.peachparts.com/shopforum/...1&d=1373657919

http://www.peachparts.com/shopforum/...1&d=1373657919

I think 28 and 29 are probably for central locking...

http://www.peachparts.com/shopforum/...1&d=1373657919

And here's the list so far

1 Battery
2 Engine coolant expansion tank
3 Dip stick engine oil
4 Engine oil filler cap
5 Alternator
6 Water pump
7 Radiator
8 Thermostat housing
9 Distributor
10 Power steering pump
11 Air intake
12 ABS pump
13 Coil
14 Electronic ignition module
14a
14b
14c
15 Fuel injector pump
16 Brake reservoir (connected to brake booster)
17 Fuse box
18 Air temp sensor (connects to a little gizmo in the air filter housing)
19
20
21 Crank case breathing tube
22 Coolant temperature sensor
23 Thermocouple for electro-magnetic cooling fan
24
25 Idle Air Control valve ICV
26 Ignition Timing Trimming Socket (a variable resistor, which retards/advances engine timing about 3 degrees per position ) (* this info came from a w124 Haynes manual)
27 Diagnosis socket
28 Brake pad wear sensor wire
29 ABS sensor wire

Can anyone help fill in the blanks?

WOW
 

For those of us who are slightly technology challenged and only half-a** DIYers, I think you have out done yourself with the pictures, numbers drawn with such precision, and the way you cut the car into organized pieces. Excellent. I for one will be printing out these pictures to use as reference material. Definitely worthy of a "Sticky".

I'm not sure if it will be of any help to you as this is a very European version - the 201.018 was only sold in Europe and Australia. I was kind of hoping someone here would say "oh yes I've seen that part before only on my car it is under the rear seat" or something like that...

I've got some more things that need identifying
 

I've got some more questions that I'll post here later on

The hunt for rust (before) October has begon!
 

Here's what I'm using as a treatment

http://www.peachparts.com/shopforum/...1&d=1373813507

I'm going round the car to do little and bit spots with this stuff.

Inner wheel arch protection plastic stuff has been removed on both sides

http://www.peachparts.com/shopforum/...1&d=1373813566

Lower body panel trim removed

http://www.peachparts.com/shopforum/...1&d=1373813635

http://www.peachparts.com/shopforum/...1&d=1373813679

Some one has been here before!

http://www.peachparts.com/shopforum/...1&d=1373813715

Once these outer body panels have been removed you can get to the rest of the sill coverings

There are obvious 8mm head screws on the underside but less obvious cross head screws behind this bit of rubber trim

http://www.peachparts.com/shopforum/...1&d=1373813815

http://www.peachparts.com/shopforum/...1&d=1373813893

Use 1/4" drive and bit combination if necessary to stop messing up the screw heads - this is way more controllable than a screwdriver

http://www.peachparts.com/shopforum/...1&d=1373813979

Pull away the sill cover - there's a bit of sealant on there too so give it a good tug!

http://www.peachparts.com/shopforum/...1&d=1373814015

And drum roll - I knew it! I bloody knew it! Just look at this =>

http://www.peachparts.com/shopforum/...1&d=1373814100

This is why I hate MIG welders folks! There's actually nothing wrong with the welding process only the dick heads who think they can weld with them. What the $$$$$$$ happened there? Was it coffee time? Couldn't be bothered to finish it?

This car has just passed a safety inspection here in Holland - which to be honest with you I probably wouldn't have expected to have been noticed under the Dutch rules - but this car still has a valid German TUV certificate which I have been reliably informed is meant to stop this kind of arsing about. They are meant to make a continuously welded lap joint as a repair...

...looks like I'll have to finish off what was half heartedly started.


Still - back to reality - I kind of expected something like this. All that glitters is not gold!

So the moral of the story...
 

...is to clean out your drains folks!

http://www.peachparts.com/shopforum/...1&d=1373814612

http://www.peachparts.com/shopforum/...1&d=1373814612

http://www.peachparts.com/shopforum/...1&d=1373814612

Just for the record =>

This car is 21 years old.

I do not expect it to be rust free

It took a lot of time and effort and luck finding a car that is this good here.

I AM happy with the car all of this rust that I've found so far can be treated and fixed quite quickly and easily. Just a little bit of welding to do and I've got a bottle of Argon on its way to me so I can even have a bash at TIG - I can't wait!

Cleaned up the plastic trim today ready for the refit. Still waiting on the argon so I can practice TIG welding before I start to finish off what was done.

I had found evidence of oil in the coolant a few days ago and so I did a flush and fluid change yesterday - today I found evidence of oil in the coolant again so I've ordered a head gasket. Good news is they are very cheap - bad news is they seem to fail quite a bit on the M102...

...typical. It looks like this car is going to suck up more of my time than I had hoped...

LOL

The car looks like it can be very nice once the rust is sorted. I really like the interior.

Yep - it is going to be more work than I wished for but in the end it should come good. With the upgrades and repair work and a bit of messing about I now reckon I'll probably end up spending most of the purchase price again. But hopefully I should have a rock solid car for my troubles. No such thing as a free lunch.

Some much needed rust proofing stuff has just arrived - and I got eyed up by the DHL delivery man! All a bit creepy really - he must like 'em rough!

Now, now, now, don't be getting all full of yourself. I should imagine the DHL guy was wondering what kind of bloke would be getting toxic chemicals delivered to his house, hmm?:P