changing my motor from 1980 240d manual with pencil style gp's to 1979 300d manual with loop style gp's. what to do about the gp's? do i just get the upgrade pencil style and wire the 5th one in?

and what about the cross member? which cross member do i use? 240d auto?

Yes, just install the retrofit pencil plugs and add a wire. Maybe it would be easiest to pull a wiring harness off a pencil 617 engine in a junkyard if there is one available? Does the 616 relay have the same harness plug as the 617 relay but with one less wire inside the harness/plug?

__________________
1977 300d 70k--sold 08
1985 300TD 185k+
1984 307d 126k--sold 8/03
1985 409d 65k--sold 06
1984 300SD 315k--daughter's car
1979 300SD 122k--sold 2/11
1999 Fuso FG Expedition Camper
1993 GMC Sierra 6.5 TD 4x4
1982 Bluebird Wanderlodge CAT 3208--Sold 2/13

Most likely the old Relay is behind the Instrument Cluster.
Some have been able to use the original Glow Plug Relay others have not. You will not know until you try it.

If you use a Ground Wire you will burn something so becareful what wire you ad. Save yourself some trouble and the DIY that others have done.

DIY Repair Links
http://www.peachparts.com/shopforum/forumdisplay.php?f=82

http://www.peachparts.com/Wikka/DoItYourSelf

__________________
84 300D, 82 Volvo 244Gl Diesel

Am I mistaken in thinking that all the pencil plug relays were under the hood?

__________________
1977 300d 70k--sold 08
1985 300TD 185k+
1984 307d 126k--sold 8/03
1985 409d 65k--sold 06
1984 300SD 315k--daughter's car
1979 300SD 122k--sold 2/11
1999 Fuso FG Expedition Camper
1993 GMC Sierra 6.5 TD 4x4
1982 Bluebird Wanderlodge CAT 3208--Sold 2/13

Go with the pencil style Andy.
Can't wait for the Squash to be back on the road!!!

__________________
Jimmy L.
'05 Acura TL 6MT
2001 ML430 My Spare

Gone:
'95 E300 188K "Batmobile" Texas Unfriendly Black
'85 300TD 235K "The Wagon" Texas Friendly White
'80 240D 154K "China" Scar engine installed
'81 300TD 240K "Smash"
'80 240D 230K "The Squash"
'81 240D 293K"Scar" Rear ended harder than Elton John

squash update

the guys at Laszlo's -in richardson- are doing a great job. the old motor is out and the new one is in place. the drive shaft is on the way to get 4inches taken out of it, but we are still stumped on the cross member and gp's.

the bad:

the ac had zer0 charge. looks like there's a leak somewhere.
rust is getting bad in the trunk. i'll have to find someone local shop to resection the trunk.
oil pan is beat up.
center drive shaft support bearing was almost gone.

the good:

the car will be a manual 300d!
all the systems will be check by an honest MB mechanic that's in my neighborhood! 2mile from home

Why are you still stumped on the GP's?

__________________
1977 300d 70k--sold 08
1985 300TD 185k+
1984 307d 126k--sold 8/03
1985 409d 65k--sold 06
1984 300SD 315k--daughter's car
1979 300SD 122k--sold 2/11
1999 Fuso FG Expedition Camper
1993 GMC Sierra 6.5 TD 4x4
1982 Bluebird Wanderlodge CAT 3208--Sold 2/13

"squash update
the bad:
the ac had zer0 charge. looks like there's a leak somewhere."

What kind of refrigerant did it have in it ?

__________________
1980 240d ,

chain elongation, cam marks reference:
http://www.peachparts.com/shopforum/showthread.php?threadid=10414

http://www.peachparts.com/shopforum/diesel-discussion/305365-9-degrees-chain-stretch.html

evap fin cleaning:

http://www.peachparts.com/shopforum/showthread.php?t=156207&highlight=evaporator

A/C thread

http://www.peachparts.com/shopforum/diesel-discussion/297462-c-recommendations-mb-vehicles.html

r12

if you have a 4 speed manual, the 240 auto crossmember is a perfect fit behind a 300 motor.

__________________
John HAUL AWAY, OR CRUSHED CARS!!! HELP ME keep the cars out of the crusher! A/C Thread
"as I ride with my a/c on... I have fond memories of sweaty oily saturdays and spewing R12 into the air. THANKS for all you do!

My drivers:
1987 190D 2.5Turbo
1987 190D 2.5Turbo
1987 190D 2.5-5SPEED!!!

1987 300TD
1987 300TD
1994GMC 2500 6.5Turbo truck... I had to put the ladder somewhere!

thanks vstech! that should be an easy find.

So, if someone has a turbo 5 cylinder with manual transmission... the 240 AUTO trans crossmember fits to support it ?

__________________
1980 240d ,

chain elongation, cam marks reference:
http://www.peachparts.com/shopforum/showthread.php?threadid=10414

http://www.peachparts.com/shopforum/diesel-discussion/305365-9-degrees-chain-stretch.html

evap fin cleaning:

http://www.peachparts.com/shopforum/showthread.php?t=156207&highlight=evaporator

A/C thread

http://www.peachparts.com/shopforum/diesel-discussion/297462-c-recommendations-mb-vehicles.html

correct.
if it's a 4 speed. the 5 speed is a longer transmission and needs a specific (TOTAL UNOBTANIUM) part made...

__________________
John HAUL AWAY, OR CRUSHED CARS!!! HELP ME keep the cars out of the crusher! A/C Thread
"as I ride with my a/c on... I have fond memories of sweaty oily saturdays and spewing R12 into the air. THANKS for all you do!

My drivers:
1987 190D 2.5Turbo
1987 190D 2.5Turbo
1987 190D 2.5-5SPEED!!!

1987 300TD
1987 300TD
1994GMC 2500 6.5Turbo truck... I had to put the ladder somewhere!

Plasma cutter and Tig or 6010,7018 .

__________________
1980 240d ,

chain elongation, cam marks reference:
http://www.peachparts.com/shopforum/showthread.php?threadid=10414

http://www.peachparts.com/shopforum/diesel-discussion/305365-9-degrees-chain-stretch.html

evap fin cleaning:

http://www.peachparts.com/shopforum/showthread.php?t=156207&highlight=evaporator

A/C thread

http://www.peachparts.com/shopforum/diesel-discussion/297462-c-recommendations-mb-vehicles.html

You are right the 1980 should have it under the hood.

__________________
84 300D, 82 Volvo 244Gl Diesel