Diesel RVs: 08/02/15

[diesel_mercedes] Re: 240D Fuel Tank Up Grade [2 Attachments]

[Attachment(s) from vwnate1@yahoo.com [diesel_mercedes] included below]

Hey ~ it worked !

How cool is that ? .

I'm trying to make another one about OM617 turbocharger overhaul but Yahoo says it can't save it and I only have a couple photos added so far , I'll try to save it , I hope I don't loose it as it's long and detailed (means : long winded and boring) .

As I've been Junk Yarding , I'll add a couple photos of what is found in Los Angeles Bone yards .

# 1 A ROLLS ROYCE

# 2 L.A.P.D. Panther radio car , they're supposed to strip off the decals before salvaging , someone could lose their JOB for this ! it's _not_ a movie car , it's the real deal .

Both are in Pick-A-Part ! .

-Nate

---In diesel_mercedes@yahoogroups.com, <vwnate1@...> wrote :

O.K.;

Let's see if I can do this :

Our 1981 240D's 17 gallon tank is simply too small ~ we travel and tour in the car a lot so I wanted to find a 300 series fuel tank .

It appears that the gasoline cars use the same tank , just a different fuel outlet screen .

I found a clean 1984 300CD in a Mercedes Junk Yard and bought the rust free tank out of it , they were very nice and allowed me to grab the hardware the yard ape scattered all over as he yanked it out , bending the filler neck a bit *:-&lt sigh

Most of the hardware was sitting in the pool of greasy water in the spare tire well , I grabbed the special pinch clamps off the fuel return and vent lines as well as a small tool kit wrench that wasn't yet rusted .

The W-123 fuel tanks come out through the trunk after you go underneath and disconnect the three hoses , fuel out , fuel return and vent .

There's a simple firewall that comes out after you remove four sheet metal screws then the four nuts and washers that hold the tank in place .

This 240 had a plastic tank , I don't know how common that is , it's worthless to me in case anyone wants it before I bin it .

The last month or so I have been fighting a bad fuel fungus infestation and had to disassemble the fuel sender and scrape about a tablespoon of black crispy sludge (fungus) out of it as the new tank came sans sender .

I parked the car with the right two wheels up on the curbstone so I could easily scrootch underneath it to reach the fuel hoses and clamps yet still get into the trunk to take the tank out .

Sadly this meant I was working under the direct sun and I nearly passed out on the sidewalk , soaked on sweat and old black Diesel fuel .

I drained out about three gallons of coffee colored (fungusy) fuel and placed it into clean waste oil containers , I don't think it's any good so I'll discard it next trash day .

Removing the old tank allowed me to get a good look at the back side of the fuel filler depression , there's a hard plastic drain hose in there that wasn't properly on the nipple , I re attached it and I'm pretty sure that's where the occasional Diesel fuel smell inside the trunk and occasionally the passenger compartment , was coming from .

No matter how carefully you remove the old tank , some fuel spills out , I was careless and spilled a good pint or more in the trunk so once I had the old plastic tank out , I unloaded the rest of the trunk and got busy with some Simple Green and a rag and garden hose , washed diligently and runsed well , now it's all squeaky clean again and no dust , no fuel smells at all .

The new (old , steel) tank went in easily , I wiggled it into place then scrootched underneath and connected the hoses before botling it down , this may or may not have been correct as it moved around a bit as I fiddled with hoses , clamps and the special rubber dust boot the Junk Yard ape of course destroyed by being careless , I used my narrowest steel spatula to *carefully* scrape the rubber seal off the old plastic tank for re use .

I re installed the firewall with it's carpet and re loaded the trunk , connected the fuel sender wire through the first aid kit hole in the parcel shelf (only two # 2 Phillips screws hold it in place) , replaced the dirty clear plastic intake fuel screen , poured in 1.5 Gallons of fresh , clear Diesel fuel and puttered off to the gas station and tanked it up , the low fuel lamp went off , 21 Gallons total filled it .

The '84 300CD tank I bought , has an unleaded gasoline filler restrictor welded into it , factory , my '84 300CD Coupe , doesn't . an '85 300D I found in the Junk Yard the next day , also had this same gasoline typ fuel tank , I don't understand it as once in a blue moon I get stuck in a truck stop that only has the BIG BERTHA fuel nozzles that barely work with the car's non restrictor filler neck .

Since then (Thursday) I have driven slightly over 200 miles and no fuel smells , no leaks so I am happy .

The filler neck gasket disintegrated , I found a passable one from the '85 Sedan but have not yet fooled with it as I found a new filler neck rubber gasket OnLine , bought it and expect it to arrive Friday 8/7 .

Pic. # 1 looking in the trunk , firewall removed .

Pic. # 2 the old 17 Gallon plastic tank and seriously fungussy sender , tools etc.

Pic. # 3 dirty clear plastic intake fuel screen .

Pic. # 4 new , clean fuel intake screen .

Pic. # 5 plastic tank full view .

-Nate

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[diesel_mercedes] 240D Fuel Tank Up Grade [5 Attachments]

[Attachment(s) from Nate included below]