I was lucky and was able to buy a 82 240D with only 52K miles on it from the original owner last week. The car is like new except It has a strong fuel smell in the trunk that is worse when its full. I replaced the rubber seal around the filler neck and replaced the fuel cap with a new one and new seal. I still have the strong fuel smell in the trunk. I removed the carpet cover over the fuel tank and I can't see any signs of leaks, around the sending unit is also dry. Any sugestions on where to look from here? Thanks in advance. Hodakaguy

It sounds like you have sealed the two main reasons people get the diesel smell. Have you let it air out for a day or two to see if that help. If that doesn't work try putting a tin of coffee back there for awhile and see if that absorbs some of the smell. Thats all the advise I can offer.

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The 1982 240D's came with a PLASTIC fuel tank...sounds like your car still has that tank..only fix is to install a steel tank...MB issued a bulletin on that problem back in 1983 or 84..

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Check the drain plug in the bottom of the spare tire compartment...it should be very, very tight. (duct tape helps in a pinch...that is why it is Mercedes gray)
Also, it could be a return hose integrity issue.

I was not aware of a plastic fuel tank on that model...I learn something new every day on this forum

Motor on

My dealer probably handled the plastic tank issue and I have forgotton.

Did MB issue a recall or a maintenance bulletin? If so, does anyone have a copy or a referrence number?, or know where to go to find out?

Thanks

Thanks, does the tank just split or ? I don't see any wet spots on the tank, I looked at the two hoses under the car that come out of the tank and they look dry. I have a custom aluminum tank that mounts in the original tank location and holds 50 gal that came out of a 300D, I wasn't going to install it since it would weight a lot when its full. If the tank is bad and is actually causing the smell maybe I'll consider installing it or locating an original metal tank. Any specific places to inspect at on the original plastic tank? Thanks, Hodakaguy

Am just rebuilding the above vehicle and have tried to look for the complete headlights at a reasonable and affordable price but am stuck. Can someone help I desparately need transport

There is also the drain tube next to the filler opening that can get plugged. If perchance some fuel does leak and this is plugged, you will get the smell as well.

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1981 240D, Auto Trans, 160k miles -- CRASHED!

I ended up finding the problem. I removed the stock tank from the car, the vent line that runs from the top of the tank down through the rubber seal and under the car had a leak in it. It was leaking right under the tank before it went through the seal. That was why it smelled worse when the tank was full. Since I had it out and already had a custom aluminum tank handy I decided to install the aluminum tank in place of the plastic one. Fit like a glove and other than loosing a little trunk space looks very stock. I have been only filling 20 gallons in it most of the time since there is no reason to haul a lot of extra weight around town, but the tank is capable of holding 38 gallons. I have taken two road trips with the new tank and its great, fill it up and you can make the whole round trip without re-fueling.

Thanks for all the great help.

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Hodakaguy
(Tom C)

82 240D - 4 Speed

Might be good to check around the fuel level sending unit under the first aid box in the rear shelf...They can leak there if gasket is bad and tank is full from the sloshing around while driving....

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1978 Yellow 300D (The Mustard Toad)
1980 Blue 240D (The Iron Toad)
1989 Grey Mitsu.4WD Mighty Max Pickup (Needs a Diesel transplant bad)

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Where did you come up with that tank??? That sounds like a mod that a lot of us could use. Imagine going 800 miles or more on a fill up, besides, you could look for the best price on fuel too.

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I bought it at a local independent MB shop. He had a older 300D that he was parting out and inside the trunk I saw this aluminum tank, he had the carpet panel out that usually hides the tank. It looks like it was custom built, its square and has internal baffles in it. It uses the stock filler port so you can fill it just like the factory tank and the fuel sender unit screws into the stock location right under the first aid kit. The pannel that hides the tank is pushed back about a foot twords the rear of the car so you loose a small amount of trunk space. I asked what he wanted for it and he said $50, SOLD! At the time I had a 300D but never got around to installing it, sold the 300D and the tank sat covered in my back yard for 3 years. I actually listed it on e-bay once but it didn't meet my reserve so I just kept it, then I bought the 240D and I'm glad that I hung on to it. The 240D is pretty much all stock and I kept the original fuel tank in case someone wanted to re-install it some day if I ever sell it. I'll try and get a couple pictures of the tank.

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Hodakaguy
(Tom C)

82 240D - 4 Speed

If that car he got the tank from had once been converted in the past to a veggie kit, I know there is a company out there (I think Vegetable Fuel Systems?) that makes custom built aluminum tanks that resemble factory units or can be made to order. Really nice looking tanks.....

Did my fuel tank, three years ago on a 123 chassi 1977 300D, in a 10degree F garage. Bear of a job with cold hands. I called MB they wanted 800 smackers for a tank NOT

Called an MB bone yard, they said, $75 in a box and shipped after steam cleaning, and leak test SOLD. Hardest part was getting those bottom gaskets to stay in place, not glue seemed to work for me.

Job is doable but alot of time it took me I would say at least 8 hours and plus three hours of cursing, but I loved it/Tom