After asking the forum members "how much do you like your 240D Manual" a few weeks ago, I finally found one: a marine blue 1982 model with about 250k miles on it.

1. Body: Paint is in good condition; right passenger door is lightly dented--either bondo or door replacement; rear bumper chrome is flaking off (I've never seen that before).

2. Interior: Seats are firm; some wood trim needs replacing; dash is badly cracked--considering dashhugger (any opinions?)

3. Engine: Seems to have received regular oil changes at least. I love the extra room in there, compared to my 300D-T. Already removed egr vacuum-related stuff; will try to make a homemade blocking plate eventually.

4. Difficult to start at first, but now starts up great after I replaced the glowplugs. Hard but very short shake at startup and shutdown--I'm thinking engine mounts and shocks. Actually the idle was set high, but when I lowered it a bit using the bowdoin cable adjustment point, the engine shook a lot, so I had to turn it back up a little (so now I know why the high idle). I'm hoping new engine mounts and shocks will solve this, but if anyone has other suspicions, please let me know!

5. Other: antenna needs replacement; odometer stuck at 233k (got a replacement at a junkyard, right at 250k, which is what I think the car actually has; hope it actually works when I put it in)

6. I can tell the shift linkage bushings are bad--rattles and other sounds coming from down there. I'll put new bushings in when they arrive tomorrow.

My biggest question, however is about the throttle "butterfly" under the air cleaner: Is this actually necessary in my car? As far as I can tell, it is mostly closed except when the accelerator is pressed 1/2 way or more, in which case it opens up gradually until fully open at full accelerator travel. Some previous posts seem to indicate that it is an egr-related item, and that it can be jammed open all the time. This would actually allow me to get rid of a bunch of linkages going across from the driver's side to the passenger side (I really enjoy simplifying things). I'm very curious about this part--what does it do? Have other 240D ownders removed or disabled this butterfly, or is it an important part to have?

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J. S. Park

'82 240D Manual 240D (sold)
'83 300D-T 230k (sold)
'84 300D-T 118k (sold)

i dont know about the butterfly. the other issues, the shaking, it sounds as if youre on the right track looking at mounts and shocks.

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[SIGPIC] Diesel loving autocrossing grandpa Architect. 08 Dodge 3/4 ton with Cummins & six speed; I have had about 35 benzes. I have a 39 Studebaker Coupe Express pickup in which I have had installed a 617 turbo and a five speed manual.[SIGPIC]

..I also have a 427 Cobra replica with an aluminum chassis.

I think you're referring to the anti-backrunning plate. It stops the engine from running backwards and damaging the motor.

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1974 240D 3.0L 4(M) - 250K -OM617.910 + 300D FW + Rajay turbo power!
1977 6.9 3(A) - 84k

I really can't say I know about that butterfly, but what I did on my '82 with the same lashup is simply replace both intake and exhaust manifolds with pre-82 versions and trash all that EGR crap.

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80 300SD (129k mi) 82 240D stick (193k mi)77 240D auto - stick to be (153k mi) 85 380SL (145k mi) 89 BMW 535i 82 Diesel Rabbit Pickup (374k mi) 91 Jetta IDI Diesel (155k mi) 81 VW Rabbit Convertible Diesel 70 Triumph Spitfire Mk III (63kmi)66 Triumph TR4a IRS (90k mi)67 Ford F-100 (??)

The butterfly inside the intake manifold is part of the EGR system- it regulates exhaust flow into the intake manifold. It is vacuumed/linkaged open when you are not at idle or WOT. Feel free to remove it/disable it, -it will change nothing if you have already disconnected your EGR system (for off-road use only =)

(my 240D is a 1982 also...slow but great cars...why do I find myself wishing for a 5cyl turbo ? =)


edit - the anti-backrunning butterfly was on 1970's MB diesels, never heard of an OM616 with one
-John

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2009 Kia Sedona
2009 Honda Odyssey EX-L
12006 Jetta Pumpe Duse
(insert Mercedes here)

Husband, Father, sometimes friend =)

Mine has a 1974 OM616.916 engine in it and it has an anti backrunning butterfly in it. I wondered about this myself when I removed the intake tube and saw a mechanically linked "throttle" plate and an additional "floating" plate in the intake. I guess it's different than the later OM616 variants.

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1974 240D 3.0L 4(M) - 250K -OM617.910 + 300D FW + Rajay turbo power!
1977 6.9 3(A) - 84k