Re read your thread. A serious error I made is I missed you had not changed the main fuel filter. I know it did not turn out to be the issue but should never be taken for granted. They are quite capable of causing many effects.

Just my two cents worth although the cent coinage has been discontinued in Canada. One should always carry a spare main fuel filter in the trunk and the tools to change it. Could save you a lot of money on the road. Include a fuel proof container to hold it in and this container can be used to hold the filter you changed out if proven not the issue. It then becomes your emergency spare.

Another suggestion although I think it probably will not work. Take the end of the Vaccum hose and get a small nozzle on a spay can. Spray some wd 40 into the line.

Crank the engine just enough to get the solvent /lubricant sucked into the ignition vacuum shutoff portion of the switch. It is a very long shot but I would try it. I do mean it is a very long shot though.

Especially since it is a 240d. the few items I mention after this have nothing to do with this problem. Check the fuel supply pressure in the base of the injection pump. Costs little to do and to me at least it is very important. Check the valve clearances if you have no ideal of the last time done as well. Plus the linkage throw to the injector pump.. You want and need all the power you can squeeze out of the 240ds. Not right now but when you have the time the three listed items should really be done if not already.

I will like a dog with a bone mention the fuel pressure check on the 240ds perhaps until I can find some proof otherwise. Low fuel pressure in the base of the injection pump destroys the 616 engines over time in my opinion. Plus has other negative effects.

These few items are reasonably important with these engines. Pretty cheap to check doing them yourself as well.