I put 50 miles on the 240D yesterday and tried the vacuum lines connected all different kinds of ways. The door locks work and it turns off using the key but now I need to pin down the tranny. Are the tranny vacuum lines routed through the switches on top of the cam cover. One of those switches "makes up" early during throttle application and it looks like the other one makes up at wide open throttle. I think the one for WOT is for the egr that is currently/experimentally not being used. The tranny shifts but it shifts early. Ideally, I would like to get a good digital pic of the proper arrangement but if that is not available I would like to get a schematic.
Also, what is the little knob closest to the left side of the steering column?
I plan on installing the cruise control actuator today and seeing if the cc works. I opened up the glow plug relay and found some corrosion on a couple terminals. Cleaned it up and I will see if it works today. The speedometer and clock do not work but the odometer does. Will probably try to pull the inst panel and see if there is anything obvious.

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Jim

Jim:

The little knob is the idle speed increase control -- full counterclockwise increases idle speed. Should have about 1/2 turn "play" in it -- adjust cable end in engine compartment to require the 1/2 turn before engine speeds up. You probably won't need it in sunny Georgia.

I think there is a vacuum diagram on this site for the 82 300D, and the 240 should be similar.

The tranny should sit in 2nd, then immediately downshift to first when you step on the accelerator -- this is the first "finger" on the vacuum box.

As I remember, there should be a white plastic line from the main vacuum hose to a T, one end of which goes to the tranny and the other goes to the switches on the valve cover. There is a restriction at the main line, make sure it is present and clear!. Vacuum should be 20" (or whatever the pump puts out) at idle, throttle closed, the drop to about 12-14" when throttle is just open, then to 0 at full throttle. Measure at the line to the tranny. Once you get that fixed, you should have decent shifting.

Early shift means you have full vacuum all the time at the modulator, it isn't being vented off.

Check the 80 amp fuse on the glowplug relay for corrosion or cracks, too -- this appears to be the weak link in this application. Quite often non-working glowplugs are this fuse being cracked most of the way across, invisible until you flex it.

If the odometer works and the speedo doesn't, the needle pivot is bad or the magnet has fallen off. I can tell you how to fix the odometer, but not the speedo head!

What to you think of that "underpowered" 240?

Peter

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1972 220D ?? miles
1988 300E 200,012
1987 300D Turbo killed 9/25/07, 275,000 miles
1985 Volvo 740 GLE Turobodiesel 218,000
1972 280 SE 4.5 165, 000 - It runs!

Got the speedo working and probably the glow plug relay. The relay was full of corrosion on the main contacts. Cleaned them with contact cleaner and emery paper. Took the speedo out and did not see anything wrong. Pulled the tumbler and will be ordering a new one tomorrow.
I will print out a copy of the vacuum line arrangement then go try to find the line with the restriction orifice in it. On one arrangement I had I almost got whiplash when it shifted to the next gear but it would not go into high.
I have read all the threads about the 240 versus the 300 and for what I will use it for the 240 is going to be fine. This is mostly flat land and I will use it for back and forth to work occasionally and around town. I will say the 300D seems quite luxurious compared to the 240D . The 240 is going to be a fun car - manual windows and all.

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Jim

Jim:

On the vacuum arrangement you had that caused late hard shifts you had no vacuum on the modulator.

Glad you got the speedo fixed, nice to know how fast you are going!

I drive the 220D (when it is working -- the tumbler went bad last week, can't start it until I get a new one and get the old one out!) with my foot to the floor all the time!

I think the vacuum supply line is white.

Peter

__________________
1972 220D ?? miles
1988 300E 200,012
1987 300D Turbo killed 9/25/07, 275,000 miles
1985 Volvo 740 GLE Turobodiesel 218,000
1972 280 SE 4.5 165, 000 - It runs!