My first Benz - '84 300D - Printable Version

My first Benz - '84 300D - Printable Version

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My first Benz - '84 300D - Raarasutra - 12-26-2012

Greetings from Montreal! I'll introduce myself really quick, and then we'll move on to the good stuff Smile

My name is Kevin, I'm about to turn 26 and I work as a cabinetmaker. I have about no history with cars at all, or mechanics for that matter! I've always loved cars, but nobody around me seemed to share the passion, so it's only in the last 3 years that I've started the huge learning curve. The first car I really started learning was the last one I've had; an '02 jetta TDI. I fell in love with diesel and knew that I would probably never own another gas car, ever. Tongue

Here is what it looked like in the end :

[Image: 8162969831_43ee9fa319_b.jpg]

So what made me ditch a perfectly working car that was cheap to run and maintain? Well, one of my buddies told me about a W123 that was just sitting in a driveway, left for dead... So I went knocking, exchanged some words, and not too long after I had my very first Benz Big Grin

Here is what it looked like for the past 6 years :

[Image: 297225_10151322668713969_1968658023_n.jpg]

[Image: 559397_10151322670163969_118388631_n.jpg]

[Image: 230840_10151322671148969_306265537_n.jpg]

[Image: 9083_10151322673613969_245632238_n.jpg]

So I had it towed to my apartment so I could do work on it outside, with the weather getting colder. Big Grin

As you can see, the interior is pretty minty! The only thing I could see when I picked it up was that it had no battery and rotten brakes. Quickly swapped my jetta's battery in and it fired right up on all 5, alternator charged like it was new and everything else seemed to be working! So when I got it home, took the wheels off and started to take apart the brakes to have the calipers rebuilt and order new rotors, pads, and lines.

[Image: 8162911180_d6cf86c958_b.jpg]

Gave it a new OEM battery, oil change, new diesel with diesel cleaner and started to do work on the rusty fenders, which I plan to swap out anyway when spring comes rolling around. Here's my buddy Jay helping me out with the to-do list Smile

Then it decided to spring a fuel leak at the inlet side of the fuel pump... (Anybody have suggestions for this?)

[Image: 8207460934_9baa51e7ed_b.jpg]

I gave the engine bay a quick once-over with some spray nine, but it'll need a lot of work Tongue

Then I got my calipers back from the brake shop. Nice work Smile

Also went to a hydraulics shop to have the flexible lines made, but out of braided stainless steel instead of rubber Big Grin

Christmas was coming around, so I decided to treat myself to a set of wheels Smile

ESM Style 002s in 16x7.5 and 16x9.

[Image: 8251398278_4e8d881fd7_b.jpg]

I came across a nice tempered glass top at work that was destined for the dumpster. I had an idea as to what to do with it Cool

And where I'm at right now :

[Image: 12205_10151417215748969_1471815508_n.jpg]

[Image: 316654_10151411328808969_1005518917_n.jpg]

All brake parts are back in, replaced the front hard lines and noticed a bad leak in the line that goes to the back. I'll have to deal with that when all the holliday stuff comes to an end. Replaced all the fuses, and have the sunroof seal to change. I also want to find out which turbine I have in there, so I can swap it out for something a little bigger Rolleyes

How can I tell? And another question for you pros, how many coils can I lop out to give my baby a healthy drop? Handles like a yacht right now Dodgy

Thanks for looking, and all advice and suggestions are welcome! More updates as shit happens Smile

RE: My first Benz - '84 300D - larsalan - 12-26-2012

That is some fantastic looking work. Some people were swapping in calipers/rotors from later models that are a little bigger for some extra stopping power. But you've gone to all that trouble already with the smaller brakes.
That part leaking on the pump is a 'lift pump' brings fuel in from the tank. They have rebuild kits and new ones of them if that's what it takes. Or maybe its just a hose clamp or fuel line needing replaced.
Can buy those pumps at peachparts, I think.

For best handling people suggest bilstein hd shocks. I just use el cheapos Wink

And I have cut 1.5 coils in the front and .75 coil off the back. Somebody might chime in about replacement lowering springs.
Or maybe cut and put in a plastic spacer. Get you a stiff spring without too much lowering.

RE: My first Benz - '84 300D - Austincarnut - 12-26-2012

too bad your guys with all the rusty cars are so far away, I have several bodies with little or no rust I'd like to get rid of.

(12-26-2012, 11:25 AM)Raarasutra Greetings from Montreal! I'll introduce myself really quick, and then we'll move on to the good stuff

My name is Kevin, I'm about to turn 26 and I work as a cabinetmaker. I have about no history with cars at all, or mechanics for that matter! I've always loved cars, but nobody around me seemed to share the passion, so it's only in the last 3 years that I've started the huge learning curve. The first car I really started learning was the last one I've had; an '02 jetta TDI. I fell in love with diesel and knew that I would probably never own another gas car, ever.

Here is what it looked like in the end :

So what made me ditch a perfectly working car that was cheap to run and maintain? Well, one of my buddies told me about a W123 that was just sitting in a driveway, left for dead... So I went knocking, exchanged some words, and not too long after I had my very first Benz Here is what it looked like for the past 6 years :

So I had it towed to my apartment so I could do work on it outside, with the weather getting colder.

As you can see, the interior is pretty minty! The only thing I could see when I picked it up was that it had no battery and rotten brakes. Quickly swapped my jetta's battery in and it fired right up on all 5, alternator charged like it was new and everything else seemed to be working! So when I got it home, took the wheels off and started to take apart the brakes to have the calipers rebuilt and order new rotors, pads, and lines.

Gave it a new OEM battery, oil change, new diesel with diesel cleaner and started to do work on the rusty fenders, which I plan to swap out anyway when spring comes rolling around. Here's my buddy Jay helping me out with the to-do list

Then it decided to spring a fuel leak at the inlet side of the fuel pump... (Anybody have suggestions for this?)

I gave the engine bay a quick once-over with some spray nine, but it'll need a lot of work

Then I got my calipers back from the brake shop. Nice work Also went to a hydraulics shop to have the flexible lines made, but out of braided stainless steel instead of rubber

Christmas was coming around, so I decided to treat myself to a set of wheels ESM Style 002s in 16x7.5 and 16x9.

I came across a nice tempered glass top at work that was destined for the dumpster. I had an idea as to what to do with it

And where I'm at right now :

All brake parts are back in, replaced the front hard lines and noticed a bad leak in the line that goes to the back. I'll have to deal with that when all the holliday stuff comes to an end. Replaced all the fuses, and have the sunroof seal to change. I also want to find out which turbine I have in there, so I can swap it out for something a little bigger How can I tell? And another question for you pros, how many coils can I lop out to give my baby a healthy drop? Handles like a yacht right now

Thanks for looking, and all advice and suggestions are welcome! More updates as shit happens

RE: My first Benz - '84 300D - Greazzer - 12-26-2012

Very very nice work ! Welcome to the forum !

Just get the basic maintenece done, e.g., all the fluids and filters changed, valves adjusted, et cet., and that is over half the battle. And yes, rust sucks. LOL.

Great Job !

RE: My first Benz - '84 300D - MFSuper90 - 12-26-2012

Sweet project! I love those wheels.
Keep up the good work Big Grin

RE: My first Benz - '84 300D - fordheaded - 12-26-2012

Nice choice in rides, Kevin!! I have the same car, same color, same miles, except blue interior. I've used mine as a daily driver for the past year. Hang with the forums and you'll pick up alot of pointers for improvement. Have fun!!

RE: My first Benz - '84 300D - Raarasutra - 01-07-2013

Thanks for the comments, I have been reading some and have learned! Having my car a 20 minute drive from where I live is kind of a pita with winter in full swing though, seeing as I have no daily (was planning on the benz filling that role) and hitching a ride has been harder than I was expecting! Got more brake line and fittings today, and have to figure out what is going on in the rear section so I can plan my actions accordingly... I'm kind of dredding working there with no lift and whatnot, but we'll see Smile

RE: My first Benz - '84 300D - Simpler=Better - 01-08-2013

Not aloot of rust up in Canadia, eh!?!?! (I'm allowed to mimic the accent I grew up just across the border)

You broke rule #1-don't make your DD a project without a backup! Looking good though, it's in great shape for being that far north. Glad to see you have the correct big battery in there.

I've got front & rear glass, NOS surface rusty rotors, worn but working taillights sitting across the border near Ogdensburg / Hamilton for cheap cheap cheap if you end up needing them.

For the lift pump you can replace the clear lines with Tygon (order from mcmaster-carr.com). Replacing the crush washers and gasket would be a good place to start. You have the desirable black priming pump already.

RE: My first Benz - '84 300D - Captain America - 01-15-2013

Kevin, NICE! Good work man. The Jetta is clean AF and the benz will be there eventually!

Love those wheels and I cut 2 coils off the fron of my car, didnt touch the rear. I wish my interior was that clean! Keep it up man

RE: My first Benz - '84 300D - sassparilla_kid - 01-15-2013

Those wheels are awesome, I need some for my w116 I think lol

RE: My first Benz - '84 300D - Raarasutra - 01-22-2013

Little update :

All the brake work is now complete! Rotten fuel lines should be getting changed tomorrow! Had my first drive in it today, which was a blast... until I ran out of diesel Tongue

I will snap some pics when I get rid of my flu and it isn't 10 000 below freezing outside Smile

Off to the inspection very soon, which means the car will be road worthy! Big Grin

RE: My first Benz - '84 300D - Raarasutra - 01-27-2013

So most of the major shit is done now!

All fuel and brake lines are brand new, including the rubber piece that is after the prefilter, so it doesn't leak anymore!

It decided it doesn't want to come to a stop when I remove the key though, which wasn't the case before... Kind of a bummer to pop the hood in -30C..

But hey! I can drive it! I put about 35 km on it this weekend! Still hasn't gone through inspection yet though. Going to a buddy's garage this afternoon to see if I can find a vacuum leak and test the shut off valve. I also want to see how hard it is to adjust the throttle linkage, cause I still have to pull back on the accelerator sometimes which sucks. I'm also going to bolt on the oem air box and filter until I can get something decent in spring!

I'm bringing my camera to the garage, so I'll snap some pics of the progress for you guys! Once it passes inspection, I'm going to remove the alda and steal the vacuum line for a boost gauge! Pretty awesome all the shit I've been learning on this forum so far Big Grin

RE: My first Benz - '84 300D - Simpler=Better - 01-27-2013

For the shutoff, run a vac line into the cabin and hook it to a 5cc syringe-easy fix that works although it's a little crude

RE: My first Benz - '84 300D - sassparilla_kid - 01-27-2013

(01-27-2013, 09:51 PM)Simpler=Better For the shutoff, run a vac line into the cabin and hook it to a 5cc syringe-easy fix that works although it's a little crude

Why not just use an open/closed vacuum switch connected to a vacuum line?

RE: My first Benz - '84 300D - Simpler=Better - 01-28-2013

(01-27-2013, 10:02 PM)sassparilla_kid
(01-27-2013, 09:51 PM)Simpler=Better For the shutoff, run a vac line into the cabin and hook it to a 5cc syringe-easy fix that works although it's a little crude

Why not just use an open/closed vacuum switch connected to a vacuum line?

That takes too long :p

RE: My first Benz - '84 300D - sassparilla_kid - 01-28-2013

Hahaa. I have a question about those mesh wheels, what offset and bolt pattern did you get? I checked out their website and it didn't seem like they had any that would really fit our cars

RE: My first Benz - '84 300D - Simpler=Better - 01-28-2013

Naysayers be damned, if it fits a Ranger/Mustang it will fit a W123. At least up to 114MPH and for long-distance towing.

RE: My first Benz - '84 300D - Raarasutra - 01-28-2013

ET20 and 5x112

I also got a power drain, never made it to my buddy's garage on sunday. Car ran fine, drove for about half an hour and stopped for a quick burger. When I came back and tried to start it, battery was dead... Called CAA, they jumped it and I drove home. Battery is still dead... What the hell could have happened ?! Now I don't mind the shut off problem much, I HATE electrical...

RE: My first Benz - '84 300D - larsalan - 01-28-2013

Need to get out the old ammeter and see if your alternator is alternating.

RE: My first Benz - '84 300D - Simpler=Better - 01-28-2013

Brushes in the regulator on teh back of the alternator. 2 screws, easy to check/change

RE: My first Benz - '84 300D - mike-81-240d - 01-29-2013

Check the voltage regulator before deeming the alternator bad. VR is a lot cheaper than a replacement alternator.

RE: My first Benz - '84 300D - Raarasutra - 06-23-2013

It's been a while! Had a couple of issues...

The motor mounts collapsed completely, leaning the engine block on the oil lines between the filter and cooler, causing one of them to fail at the filter fitting. Lost all my oil on the highway Tongue

Towed it to the garage, and called up the dealer to get replacement lines. And of course, one of them is discontinued... So after a hell of a long wait, the one that was available came in and the shop started to process of replacing it and hopefully the other one was good. The mechanic gave me some good news and some bad news.

I asked for the bad news first ; the collapsed oil line rust-welded itself into the oil cooler, breaking both during the removal process.... Guess how much the dealer wants for one of those? $1300CAD pre-paid non-refundable and ordered from ze germans.

I had a heart attack and asked for the good news ; the other oil line was okay, and the guy found an oil cooler for half the price at another garage. I sighed and gave him my approval.

So I had him change the failed oil line, 2 motor mounts, patch the hole under the gas pedal, install a spring so the throttle linkage would come back all the way and check for the power drain, which he didn't find, but it mysteriously disappeared anyway.

Now I need to figure out why it shifts gears too quickly which is making it slow, figure out what I can do to replace the rusted out accelerator bracket under the pedal, patch the remaining holes on the body and have it inspected (finally...)

I've made some good progress in the couple days I've had it back from its 2 month layover in some sketchy garage;

[Image: 9117673410_477de7f36f_b.jpg]

It works!!

[Image: 9117676878_946a76b28f_b.jpg]

And here is where I mounted it:

[Image: 9117680152_48d05f6ba9_b.jpg]

Little video of the gauge before I stuck it in its final resting place :

http://www.flickr.com/photos/raarasutra/9117669226/

Some of the body work I've been doing :

[Image: 9118486605_e8d6e480be_b.jpg]

And does anyone know what this thing is? And what I can replace it with that is bolt-on?

[Image: 9118520771_68ef41f15d_b.jpg]

Don't worry about the crappy body work, it's only so I can get through inspection Smile

Will be getting fenders that are in way better shape!

RE: My first Benz - '84 300D - mike-81-240d - 06-23-2013

Holy huge pictures!

RE: My first Benz - '84 300D - Raarasutra - 08-03-2013

I've done a bit since the last update. Got the body to where it would pass inspection, which is boring stuff so I'll skip that.

Got it through inspection and plated and road legal! Best thing that happened to the car since I bought it. So I drove it a bunch, and went to the local "Euro Tuesdays" for the first time with the benz, but then my dad called me on my cell and told me I had left a mess in the driveway...

The car sprung a diesel leak at the back, one of the rubber junction hoses had been torn through by the rusted out clamp. That was an easy fix, but what WAS a pita was the huge mess that made with a full tank of diesel. Lots of kitty litter and siphoning and filtering and all that unpleasant crap. Anyway, on to some cooler stuff.

One of the rear shocks was shot and causing some bouncing and shit, so I ordered some HDs for all fours.

[Image: 9427290162_d45e7af146_b.jpg]

And while I was doing suspension crap, I thought I'd cut a bit off the springs!

[Image: 9427205126_13e3afa82c_b.jpg]

Yeah, my shoe caught on fire from being stupid like that. Anyway, I ended up removing 1.5 coils up front and 1 from the back. The ride is so much better that I can't find the words to express how awesome it is.

So I had ordered a Nardi from Thailand and an adapter from some other place, which I spared no time installing :

[Image: 9424430483_70036db104_b.jpg]

Just needs a horn button now Smile

I still have tons of work to do, mainly I want to figure out what's going on with the (electrical) power. I'll have to check the voltage regulator and engine block ground (from what I've read) and see if the alternator is still good since I tested it before buying the damn thing. I'm also too broke to buy tires for my wheels, and I need to have the front bores machined so they can fit. I haven't taken pictures of the car since I lowered it or anything, but I don't really want to anyway because the car looks like crap to me with the fenders being primed and some bare filler on a door and rust and stuff.

Anyone have some spare euro headlights I could have for le cheap? Smile

Until next update!

RE: My first Benz - '84 300D - willbhere4u - 08-03-2013

Nice job what do you mean by machining the front bores? you can but a new voltage regulator for the alternator its way cheaper than replacing the whole thing they can charge and still have a bad diode in them that causes a drain.

RE: My first Benz - '84 300D - Raarasutra - 08-03-2013

The center bore from the front wheels is too small, so I have to get them machined... Sad

And yeah, I'm about to order a regulator from MS just in case it fixes things. The symptoms mentioned are exactly what I'm experiencing so it's a no-brainer to buy one really.

RE: My first Benz - '84 300D - lgreeley83 - 08-03-2013

Why is the boost gauge hose so gigantic looking?

Aside from the fact that it is, is there a reason for that big a line to the gauge?

RE: My first Benz - '84 300D - larsalan - 08-04-2013

I would say that's unnecessary and could lead to minute turbo lag. Like super minute, that circut is just there to feed the gauge. There's no reason it needs to be as big as a fuel line. However, I doubt there is any problem with that much volume of line. imho, ymmv

RE: My first Benz - '84 300D - Raarasutra - 08-04-2013

I had to go with the fittings and line I could find locally, plus the gauge isn't really made as a 'boost gauge', and it has a 1/4 NPT fitting at the back and a wall mounting bracket for machinery. It did cost me 10$ though, and another 10$ for the line and fittings, which is MUCH cheaper than the boost gauges I was looking at Smile

I didn't notice any lag, and I really like that gauge, I think it fits in and doesn't have that "JDM-tuner-LED-china" look to it. What I might end up doing is try to take it apart and yes, reduce the size of the fitting/line. The reading I get it wobbly and I'm guessing that's the huge line's fault; less air mass, less variations?

I'm also looking for a way to get rid of the huge air bowl and filter. I just don't know what to do with the "vent" tube from the valve cover yet.

RE: My first Benz - '84 300D - Simpler=Better - 08-04-2013

You can run the crank vent to an oil separator (either cut the stock one out, or make one) then plumb it back pre-turbo.

For the gauge, I ran a similar cheapo gauge with 1/8" line and didn't get any fluxuations. I love gauges in teh vents Smile

RE: My first Benz - '84 300D - lgreeley83 - 08-04-2013

(08-04-2013, 02:03 AM)larsalan I would say that's unnecessary and could lead to minute turbo lag. Like super minute, that circut is just there to feed the gauge. There's no reason it needs to be as big as a fuel line. However, I doubt there is any problem with that much volume of line. imho, ymmv

I thought I read bad things about big line to gauge but it could be that I've just never seen one that big.

RE: My first Benz - '84 300D - MFSuper90 - 08-08-2013

turbo would fill that line with boost like licky split no problem. I don't think its a problem, just a pain in the ass to plumb.
If you don't mind me asking, how much did you pay for the rims?

RE: My first Benz - '84 300D - Raarasutra - 08-08-2013

They came out to around $750 CAD to my door step, including tax, shipping and customs.

RE: My first Benz - '84 300D - Raarasutra - 09-12-2013

I thought I'd just leave this here as a teaser. Picking up tires and bolts tomorrow afternoon Smile

RE: My first Benz - '84 300D - mike-81-240d - 09-14-2013

Excellent. With my front wheels I ended up boring them out myself with a cordless drill and a whole saw bit. Worked perfectly.

RE: My first Benz - '84 300D - Raarasutra - 09-14-2013

I measured the fronts and did the math.. I would've had to bore the wheels right into the hex cap's thread, so that was a no-go. I ended up removing the bearing dust caps and leaving the 15mm spacers in. That's the only way I could mount them Undecided

I really think the dust covers are really huge for nothing, so I'm going to draw up an alternative and see about machining costs Smile

If it works out, I'll share the CAD or whatever format I end up using. Anyway, on to more interesting stuff!

[Image: 9741770297_fd23de3610_c.jpg]

Got new Nitto tires for the front in 205/40/16, rears are well-used Azenis in 215/45/16. I know the sizes are all wrong and my speedo is probably all out of wack Tongue

I may end up swapping the fronts for 195/45. Maybe if I can get my hands ahold of some 50s I'll see if they clear the wheel wells. Here is how the car looks right now :

[Image: 9743889682_d960b0ffbb_b.jpg]

Yeah, it's pretty low... Won't be long before I scrape through parts of the exhaust Big Grin

I'm going to stick the rubber spring pads back in to get the extra few mm, think I'm going to need it. Lowering springs in the future I'm guessing, so I can be maybe just a little higher but much stiffer.

Hope you enjoyed my shenanigans! Cheers

RE: My first Benz - '84 300D - MFSuper90 - 09-14-2013

Normally not a much of a low car fan, but that thing looks sickkk
Love it