Hi, I just came from the MB shop w/ my E300 still randomly stalling -a safety hazard on the road. We're stumped - so my MB Tech referred me to this site...

Stalling: Sometimes it just wont start, other times it stalls in motion. Total random, no warning, just cuts out very abruptly. Usually I can pull of the freeway, sometimes in town or construction everyone has to wait behind me... Sometimes restarts, sometimes won't. Sometimes green/red lights flash, sometimes not. Getting worse over past 18 months from ~monthly to weekly to now almost daily. Usually starts after pounding on ECM box, not always. Have Snap on Scanner on it. Sometimes looses communication when stall, sometimes still communicates and says everything OK including Drive Authorization, etc. Sometimes random codes like P1480 glow plug, P1617 control module, P1622 inj pump shut off, but usually just the ABS/ETS codes below.

ETS/ABS: Repeatedly throws P1520 cruise switch, P1702 stop lamp, and P500 VSS codes. Sometimes ETS/ABS lights on, sometimes the yellow triangle, sometimes the speedo/odo won't work. Sometimes all OK.

Parts thrown at it so far: Changed the brake switch and the ETS/SPS module -no difference. Regrounded all grounds, check harnesses wiggled terminals for corrosion - no difference. Purchased used IFI module (Engine ECM) -cannot get car to accept it. At this rate I'll soon have more money in parts than the car is worth (new IFI alone is $1400)

Questions: Should I throw an R25/2 Throttle position sensor at it? Or other? Or keep working on the IFI swap? What do I need to swap the IFI? Believe it is Dos2 drive authorization? So do I need DOS unit from orig IFI vehicle as would be locked together after 40 starts? Or can it be flashed somehow (won't accept flash from my Snap-On or either the MB tech's expensive scanners)?

Thanks in advance for any assistance -would be greatly appreciated -hate the thought of having to drive a GM gasser again!!! Kevin.

K40 relay???

That's what I was thinking. It's about a $100 part in the black box in the rear passenger-side corner of the engine compartment. Do a search on this forum. I had the same stalling issues and some random error messages until I replaced it.

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2004 VW Jetta TDI (manual)

Past MB's: '96 E300D, '83 240D, '82 300D, '87 300D, '87 420SEL

The "cuts out instantly. Anywhere, at anytime bit" suggests either the K40 relay or IP shutoff valve are at fault.

With the other grimlins present I'd do the K40 first.

MB's SDS should marry the IFI to the car for you. Not mcuh else will. But, is a moot point as the K40 is more than likely your sole problem. Perhaps you can return the IFI?

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Terry Allison
N. Calif. & Boca Chica, Panama

09' E320 Bluetec 77k (USA)
09' Hyundai Santa Fe Diesel 48k (S.A.)

Yes, K40...if that hasn't been tried certainly give it a shot. The solder joints on them are notorious for causing the problems you describe and the fact that it has gotten worse over time says it is very possibly the cause as the joints will become more and more "iffy" as time and vibration/temperature variation goes on. Try that and report back.

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Marty D.

2013 C300 4Matic
1984 BMW 733i
2013 Lincoln MKz

My K40 relay caused the same problem till I replaced it.
Steve

Sounds like the K40 issue. The K40 runs the IFI system. From another post somewhere, the K40 is like the achilles heel of the car. They don't go out often but at this age it's safe to replace it.

Check out this thread player!

http://www.peachparts.com/shopforum/showthread.php?t=151581

That URL is invalid, Mich.

I was able to solder my K40 module. If you want to try this, there are a few tricks to make it actually work.

Here it is again. This link has the part number as well...

http://www.peachparts.com/shopforum/showthread.php?t=151581&highlight=K40

You guys are GREAT! I can't believe all this was resolved w/ a K40 relay for $102!!!! That night I resoldered the connections on my orig K40 which didn't help, but I ordered a new K40 in the next morn and a day later I was no longer randomly pulling off on the freeway shoulder, and I haven't had an ETS / ABS code since. In fact I haven't had any codes since. I wend back to the schematics to see how I missed this. I had assumed it wasn't a power to the IFI issue since I could read voltage at correct levels via the unit itself. What I discovered is that there are multiple power sources to the IFI module. So even though it itself thinks it has power, it may not. 2 lessons: 1) start w/ this forum. 2) always go to the schematic and trace ALLL power supplies and grounds, and put a meter across ALL of them before assuming a module is bad.

Anyone need a used IFI or used ETS/ABS module for a 1996 E300?

Thats great great news... The irony is that mine is now starting to do the same thing.....
I ordered mine yesterday from Phil I inspected the joints but didn't really see anything cracked.

Look in the performance forum. I forget his name, but someone wanted the connectors off of one to use for a Megasquirt or similar system for a V12.