More discoveries...

Whenever I disconnect the red single wire from the headlight switch, no discharging. That wire jumpers over to 2 ignition wires and 1 to the #2 fuse. THAT's where the problem is. I'm outta time for tonight, but at least I got that far...

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'90 300SE --- 173k miles --- (Odometer just stopped working!)

'85 Cali 300D --- 193500 miles --- (Second one) Sold Nov '10

'82 300TDT --- 236,xxx miles --- (My first one) Sold July '09

Hey my 240d did the same thing my altenator had an internal short. When i disconected all fuses i still had a draw of 11.6 finally i unpluged my altenator and lost the draw! Please check the altenator i work and Advance Auto and i know what crap our electronics are. Dont work to death because of a crappy part!!

I checked the alternator, it wasn't the problem. I traced it to the headlight switch/ignition so far. When I disconnect the red wire from the headlight switch, the problem stops. So that leaves glowplugs, ignition switch, or starter solenoid, right?

I'm going for the starter solenoid first. I just put it in, but it's a reman from autozone (2nd one!). So it seems logical to try it first.

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'90 300SE --- 173k miles --- (Odometer just stopped working!)

'85 Cali 300D --- 193500 miles --- (Second one) Sold Nov '10

'82 300TDT --- 236,xxx miles --- (My first one) Sold July '09

I had long standing alternator issues that sound like yours.

The issues disappeared when I bolted the started motor to the plate that holds it to the side of the engine with 2 bolts. Don't ask me why, it just worked, so I thought I would mention it.

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1983 240D Silver/Blue "Sadie", unknown miles. 100k miles on WVO single tank, converted to 2 tank about 10k miles ago, FPHE, Injector Heaters, Aux Fuel pump. Alcohol/Water injection. Frantz oil bypass filter
1992 300D 2.5 Turbo Green/Tan "Jade" 267K miles Stock.
1992 300D 2.5 tan/tan "Rocky" on 2 tank WVO. Pressure actuated Turbo "rat's nest" surgery completed. 197k miles

Hey guys!

Thanks so much for all the suggestions. It turned out to be the neg. on the starter was loose and shorting out everything! So I put a $120 Saab alternator in for nothing! Oh well, I really wanted to try that alternator anyway.

New problem after everything is fixed....
I had the radio out, so when I went to push it and it's wires back in, I removed the climate control switches to aid in the wire stuffing. Well, now I don't have AC! Btw, Houston is freakin' HOT! So, where should I start on this? I see the compressor spinning and the aux comes on when the engine temp gets high enough. Bad controls? Suggestions?

Thanks!

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'90 300SE --- 173k miles --- (Odometer just stopped working!)

'85 Cali 300D --- 193500 miles --- (Second one) Sold Nov '10

'82 300TDT --- 236,xxx miles --- (My first one) Sold July '09