Just thought I would update you guys since you seemed interested enough to help with advice and pass me some virtual experience.

Well, the underside of the car was pretty nasty with oil and grime, so I got completely covered in tar like ooze. It came off, and so did the engine mount bolts and then the engine mounts. For the record, the next time (if ever) I try this, I will take the bolt to the strut coming off the engine off first, then jack the engine up on the driver's side, and remove that irritating little cover piece. That thing made getting the 6 mm allen wrench into the socket head capscrew on the engine side a nightmare. The other side came apart with no problems. Going back together was also no real challenge, once I had the geometry of the situation figured out.

I also managed to find the transmission mount, which was covered and packed solid with goop. That device essentially disintegrated with the strain of the hydraulic jack lifting the motor so that chunks of the rubber kind of extruded out and fell in my face. So I ordered another one from Fastlane today.

While under the vehicle I removed the starter after verifying it was dead. Once out, it was kind of loose. The unit is made of three cylindrical sections, the part that engages the ring gear on the flywheel, the center section that I expect houses the motor, and the end cap that you make the electrical connections too. These are not loose enough to fall apart, but they are also not tightly bound together, as they will rotate 5 or 10 degrees relative to each other. Has anyone seen this before?

I ordered a new one of these too, after talking to the local dealer who says MB only stocks the one for the 300D/SD and it fits on the 240D, from Fastlane today. I selected the one described as "heavy duty" which is only listed for the 300D turbo/300SD and 300CD vs. the "light duty" one for the 240D at FastLane. I called the Fastlane guys and got their confirmation that the unit should fit.

So, I cannot verify my theory on hard starting just yet, but I am still optimistic that a strong starter, and a properly restrained engine will make the difference. The car just has too much liveliness and strength to be worn out just yet. I will post the final results, whatever they are, when the job is done.

Jim

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Own:
1986 Euro 190E 2.3-16 (291,000 miles),
1998 E300D TurboDiesel, 231,000 miles -purchased with 45,000,
1988 300E 5-speed 252,000 miles,
1983 240D 4-speed, purchased w/136,000, now with 222,000 miles.
2009 ML320CDI Bluetec, 89,000 miles

Owned:
1971 220D (250,000 miles plus, sold to father-in-law),
1975 240D (245,000 miles - died of body rot),
1991 350SD (176,560 miles, weakest Benz I have owned),
1999 C230 Sport (45,400 miles),
1982 240D (321,000 miles, put to sleep)