Just bought mine and havent started tinkering yet, but first...are all the vacuum lines in the car the same size? If I were just going to replace all of them, could I buy a bunch, or do I need different sizes? Thanks. James.

On a 300D there are different sizes. By that I would think there are also different sizes on the 240.

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1985 300D 198K sold
1982 300D 202K
1989 300E 125K
1992 940T

"If you dont have time to do it safely, you dont have time to do it"

"The democracy will cease to exist when you take away from those who are willing to work and give to those who would not."

With the obvious exception of the main line to the brake servo I believe they are all the same size.

One thought, they are marked differently or different colors. I almost did the same thing you are talking about when I did mine but then decided to just get all the correct lines and I have found doing so the be beneficial, well under the hood and where they go through the firewall anyway.

The "correct" lines were pretty cheap I think I had less than $200 in all new lines, rubber connections and check valves.

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'83 240D

$200 for vacuum lines!!! and that's cheap? You must be loaded lol. The lines are easily fixed and patched for a few bucks. Even the broken main hard vacuum line is easily repaired.

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85 300D turbo pristine w 157k when purchased 161K now
83 300 D turbo 297K runs great. SOLD!
83 240D 4 spd manual- parted out then junked

Related questions: there appears to be some oil residue in the vacuum lines of my '79 240D. I haven't yet figured out whether this was due to a problem that was subsequently fixed, or whether I have an ongoing issue.

1. Any guesses on where the oil is coming from? Vacuum pump? The pump currently pulls a fairly decent vacuum (25" Hg). I don't think it is brake fluid, but I could be wrong I suppose.

2. Are there any recommended ways to clean oil residue out of the lines? Or is it a lost cause at this point, and I should just resign myself to the $200 replacement plus hassle?

My vacuum system seems kind of inconsistent. I found that it held enough vacuum overnight to operate the door locks (all of them, I think). Yet, when I put the Mity Vac on the small line that comes off the brake booster line and feeds into the cluster of small lines I found that I had to pump like hell to get vacuum, and it bled off quickly. I kind of suspect the ignition switch or the injection pump diaphram, since the car just barely shuts off.

Thanks for your opinions,

Kurt

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- '79 240D - engine swap complete! Engine broken in! 28-31 mpg! Lovin' the ride!
- '86 190D (W201-126) - 2.5 NA engine, 5 speed, cloth interior, manual climate controls, 33-34 mpg (sold to forum member).

I'll agree that most of the lines are the same size, the different color combinations helps locate the other end and what it is for.
gastro... you'll have to be more specific, which line/s? One of which goes to the shut off actuator will have oil in it when the actuator fails.
Your main line will probably get oil in it if the vac pump fails, not sure if it would be intermittent, or just a complete failure.
I've not done the same test as yourself, you're pulling vacuum the wrong way when you do that.
The shut off actuator is the usual suspect.

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83 SD

84 CD

It was noted on the pre-purchase inspection that the shut-off servo leaks; is it a big job to replace?

Thanks,

Kurt

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- '79 240D - engine swap complete! Engine broken in! 28-31 mpg! Lovin' the ride!
- '86 190D (W201-126) - 2.5 NA engine, 5 speed, cloth interior, manual climate controls, 33-34 mpg (sold to forum member).

Its not a hard job, 4 bolts, BUT you have to be careful that the new switch hooks the connection in the IP, do a search as a job not done correctly will result in a 'run away' engine, very ugly, just something to be aware of.

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1985 Euro 240D 5 spd 140K
1979 240D 5 spd, 40K on engine rebuild
1994 Dodge/Cummins, 5 spd, 121K
1964 Allice Chalmers D15 tractor
2014 Kubota L3800 tractor
1964 VW bug

"Lifes too short to drive a boring car"

No, as mentioned, not difficult and you'll need two paper gaskets that sandwich the metal one, they have a notch, makes it easy to hold in place during installation.
You see the hook on the end, pay attention to the orientation and install the new one in EXACTLY the same position. The vacuum line nipple is also helpful in deciding this.
The hardest part for me was getting that furthest away bolt in.

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83 SD

84 CD

Toomany, you're amazing... appreciate the pictures.

Kurt

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- '79 240D - engine swap complete! Engine broken in! 28-31 mpg! Lovin' the ride!
- '86 190D (W201-126) - 2.5 NA engine, 5 speed, cloth interior, manual climate controls, 33-34 mpg (sold to forum member).

Happy to help.
Let us know how it goes.

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83 SD

84 CD