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Car Forum / Mercedes-Benz Cars / June 2005

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Need Input on Troubleshooting 1984 190D That Won't Start

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Michaela - 15 Jun 2005 02:08 GMT
I've got a 1984 190D that will not start. I removed main fuel filter &
found a lot of dirt in it - cleaned it out completely & reinstalled it;
still won't start. It turns over very strong; just won't fire off (so it's
not starter.) Only have had the car about 6months - I am well-versed on
gasoline engines, but know little about diesels. Read in a book from
library that a very small particulate of dirt could clog up the needle in
the injector - since I found dirt in filter, is it likely that this is the
problem? The fuel pumping system is fine - getting lots of fuel to main
filter and I feel injector pump is o.k. because fuel is going to
injectors, but did not check the injectors themselves as yet. When I
remove them, is it advisable to replace any gaskets or seals that I will
encounter? As well, the book said the injectors need to be torqued down to
a specific pound rating, so I'm hesitant to remove 'em and not be able to
torque them right; is this imperative? Are there any relays or things of
that nature that would prevent starting or is it most likely fuel-related?
The car ran great prior to it not starting, compression is probably very
good. Got the car 6 months ago - it sat for 5 years without being started
cause former owner died. I was told, "If you can get it started, you can
have it." I took a good battery to it; installed it; and the car started
immediately on first fire - didn't even hesitate!! I drove it for 6 months
but never changed the fluids, as they looked clean before I started it. But
with it sitting for so long, could a lot of stuff be in the system that
finally caused blockage or something? Any input I might receive would be
most sincerely appreciated. Thank you; Michaela
T.G. Lambach - 15 Jun 2005 03:10 GMT
STOP!

First of all, one doesn't "clean out" a fuel filter, it's replaced with
a new filter.

Since you opened the fuel system it must be purged of air; this can be
done with the hand primer pump that's probably below the injection pump.
(I don't know this model). Look for what appears to be an 7" x 1.5"
aluminum pipe pointing at you that has a round black plastic top.
Unscrew that top and start pumping to draw fresh fuel into the filter(s)
that were emptied earlier. It should be fine after ten or twenty
strokes, screw the top back on to the hand primer pump.

Then, leave the fuel system alone; that's probably NOT the problem.

Diesels use glow plugs to heat their cold cylinders prior to starting;
that's the light with the coiled wire that's on the dash - it ought to
light for about 10 seconds when the key is turned ON and then go out
signaling the engine is ready to be cranked. There's a glow plug relay
and on it, a metal fuse (fusable link). Chances are that if this is the
first instance of no starting the link is broken cutting the power to
the glow plugs.

The engine won't start without working glow plugs. So you need to
investigate them to ensure they are working. Start by finding the glow
plug relay - trace the wires from the glow plugs - 4 wires on the side
of the head, near the injectors - back to the relay. The glow plug relay
may have a plastic cover over the link. Replacement links are available
from a M-B dealer and others for about $1 or $2 each - your car needs
one - plus a spare.

If you are confident that the glow plugs are working but that there's no
fuel being injected then the next suspects are either an air leak in the
fuel system or that the engine's vacuum powered shut down device no
longer releasing when you want to start the engine. Air leaks are fixed
by being sure all fuel hose connections, filters etc. are secure. The
shut down device is of the "right age" to be suspect. Its a small
bellows that's on or inside the injection pump that pulls the fuel rack
to OFF when you shut down the motor. The bellows wears out, gets oil
logged and fails. Usually the engine doesn't stop and needs to be
stopped by pressing the STOP lever on the throttle linkage.

Diesels are simple motors to maintain. Change the oil, change the
filters and leave them alone.
Hope this helps you.
Tiger - 15 Jun 2005 16:10 GMT
Ditto... I'd suspect glow plug system.
Michaela - 17 Jun 2005 07:15 GMT
Just read all of your replies, Gentlemen; thank you kindly for all of your
suggestions. To T.G. Lambach: the library books told me there is no hand
priming pump on the 190D. Regarding the glow plugs - I will definitely
check the relay and fusable link for the glow plug system and then the
shut down device if I find nothing wrong in the glow plug system.  Your
point about changing all fluids is well-taken, and I shall do so before
putting her back on the road.  To Wan-ning Tan: My 190D is a 2.2, and yes,
there's no hand priming pump as you said. The fuel tank never ran dry; it's
about 3/4 full right now. I will check the glow plug relay, fuse strap, and
resistence.
Thanks for the tip on the "Cx" spec oil as opposed to "Sx" spec - that's
very important, I am sure; since it uses compression to start. To Tiger: I
concur.  Thanks again, all of you, and I
intend to start early Friday morning to check the automobile out, and I'll
let you know how it goes!
Regards, Michaela
Wan-ning Tan - 15 Jun 2005 06:38 GMT
I have a 84 190D too.  MB diesels in this OM60x series (e.g. 601 in 190D
2.2; 602 in 190D 2.5; 603 in 300D/300SDL/350SDL) no longer use the hand
primer pump.  Just crank it hard.  It may take more than 2 minutes to
fill up the entire fuel system if you ever let the fuel tank run dry!  I
thought replacing the filters won't drain the entire system, unless you
really let it open for extended period.

Glow plugs are important to get it start.  The relay is on top of left
front wheel well, a black box about 4"x4".  Check the fuse strap (80A,
$1 part), and check the resistence of each plug (should be around 1 ohm).

Injectors may be dirty but I would leave them as the last resort.  One
injector failure will cause rough but not no start.  Multiple failure is
unlikely considering it was running fine.

If the car has been sitting for 5 years, I would change all fluids (oil,
ATF, brake, PS).  Note that most motor oils are for gas engines.  You
need one that meets Cx spec (compression, instead of Sx spec, for
spark).  ATF is Dexron II.  Also, MB recommend changing brake fluid
every two years anyway.  And I believe MB calls ATF for the power
steering fluid.

> I've got a 1984 190D that will not start. I removed main fuel filter &
> found a lot of dirt in it - cleaned it out completely & reinstalled it;
[quoted text clipped - 20 lines]
> finally caused blockage or something? Any input I might receive would be
> most sincerely appreciated. Thank you; Michaela
T.G. Lambach - 15 Jun 2005 19:41 GMT
Excellent advice and to this specific model.
 
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