The Bonnie Situation

Bonnie Runs

2007-09-07T16:37:00.000-06:00

And Bonnie speaks - this is after the diesel purge, but before the valve adjustment.

My Valve Adjustment wrench

2007-09-07T10:21:00.000-06:00

My attempts at making one of the valve adjustment wrenches. I happen to own a chiminea, where I heated a Craftsman tool. The Craftsman is a long one. After heating, I put into a vise and bent by tapping with a ball peen hammer.

Here's how he turned out - we'll test tomorrow.

And one more

2007-08-21T21:53:00.000-06:00

BenzBoz Pre-Owned Mercedes Parts is a great Ebay parts seller. Not only does he have stuff properly labeled, he gets it out fast - faster than a lot of places. I've gotten a driver door window regulator & motor before - I paid for on Wednesday, got it on Saturday. And, at the time I needed it. THe mailman came, and I just had the old one out. But, I still had my lemonade break.

Another new friend

2007-08-21T21:50:00.001-06:00

We have another one in the form of a Mercedes 126 enthusiast - www.mbw126.com. He has one heck of a video on rebuilding an AC compressor. HH is a real cool guy, and is going to list more!

A new buddy

2007-08-21T21:28:00.000-06:00

Bought a door from a real nice guy last week, Mr. Ray Petty, who sells on Ebay but you can also contact via his web site . He is super nice, and will tell you what he has. He doesn't run a store front, just what part do you need, etc. Can't say enough about him.

Houstoneuropean.com

The light at the end of the tunnel

2007-08-14T10:26:00.001-06:00

OK - more progress. Last night, we got her out of the garage. The transmission bushing clips are installed. Charles had to take her around the block a couple of times, to get the radiator/cooling system flush to circulate. He got to drive her. He said it felt good. The speedometer works. We finally got her started by shorting across C105. Had to use a lot of starting fluid. It took quite some time, but I bled the fuel injection system. Finally got the priming pump to move, and the ends of the injectors cracked open. Tha 17mm wrench fits tight. Found out that we can pull her off just like a John Deere tractor. We drained the radiator, and got a lot more crap out. The water was red initially, so it may need some more flush. For this one, I think we'll use the Mercedes citrus flush. We got hte instrument cluster lights yesterday, along with the new flasher relay.

This morning, she left for the body shop. Hopefully, we can get the door closed soon.

More Progress!!!

2007-08-07T23:14:00.001-06:00

OK, more sweet progress - we're cooking now. First, we did the Lubri-Moly purge of the injectors.

Here's the temporary line hooked up to the inline fuel filter.

Here's the return line from the spin-on fuel filter.

I used a 2 liter Diet Coke bottle as the purge material container. This probably was not one of the uses considered by Del Meyer, the inventor of polyethylene terepthalate. But, it worked. For the 300SD, I used 4 feet of 1/4" hose. I cut it in half. If I did it over again, I'd used 2 1/2 feet for the feed, and 18 inches for the return.

Here is the fluid, shortly after starting turning a bright red. Shortly after this, the smoke from the exhaust cleared, and the engine purred.

Here we are near the end, showing a brilliant black, and also a side shot of the AC drier, something I need to soon replace.

A few minutes after the purge, I looked at the gauges. The tach was still not functioning, so I cleaned the contacts, then hit them with a little white lithium grease. The tach showed a smooth 750 rpm.

The fuel tank gauge worked nice, the oil pressure gauge indicated 4 bar (which I need to check), and the temperature showed 50 degrees C. THe most important thing, the gauges were working.

Also on the night's activities was the replacement of the air cleaner mounts. This got done as well.

An undershot.

Another great site

2007-08-07T22:53:00.000-06:00

I've found another great site for MB lovers, with some great rebuild info. Especially the compressor rebuild. I recommend him as another friend with a Benz.

Small Victories, with setbacks

2007-08-05T22:01:00.000-06:00

We got Bonnie started, with a screwdriver across C105. But, some of the parts have not worked out as I would have liked.

The front cowling is back in , with the windshield wipers.

The new back window does not fit.

Shot of the vacuum accumulator in the left panel.

Little bit of JB Weld on the left windshield mount.

Primed area - where the body drain kicks in. Taped up with gaffe tape.

ANother shot of that damn back vent window. THis really pisses me off.

The old thermo vacuum switch.

Front transmission busing replacement.

The rear - it is in.

Replaced the ignition switch.

Even More - it's getting close

2007-07-30T05:42:00.001-06:00

More progress: Here's the rheostat dimmer switch for the instrument cluster. It has been cleaned and reinstalled.

Here is the speedometer. The needle has been repainted to be able to be seen.

Here, though, is my favorte accomplishment, or rather that of a neighbor who has a wire welder. I could not locate the grommet for the wiper mechanism. So, we took a #12 stainless steel washer, reamed it out, and welded it onto the cap. I cycled it for several minutes, and it has held. Now I need to clean out the cowling.

ANother shot of the wiper transmission. We also lubed the wiper shafts themselves.

TOday - title & registration, along with others. I've almost got the left panel off, so I can kill those dents.

A busy day

2007-07-29T10:48:00.000-06:00

A new hood pad! I could have gotten the left side aligned a little better; I think about 1/4" off there.

The old look

The home made instrument cluster removal tool.

The back of the instrument cluster.

The left side of the instrument cluster

The instrument cluster, with al of the back side screws on the picture of the back of the instrument cluster. Thanks, Richard Sexton!

The plugs out of the driver's side window motor.

I washed it down with contact cleaner, but pulled it out anyway since the mailman delivered a new one.

This is the hood area, after I had sanded and primed.

The old window motor, which is now added to the used parts bin.

More progress - slowly

2007-07-24T22:51:00.000-06:00

Pictures of tonight's work

Here's the radiator drain plug, with the o-ring

Here's the Hirschmann antenna. I've printed out a diagram for parts, but this one may be best to send to Walter Odemer.

Front underneath the carpets on the driver's side - needs a youngster to clean out.

Ditto for the back seat area. I did find wasp nests underneath the back seat.

With a hood pad on the way, we need to get the crap off the hood. I used a citrus based stripper, non-flammable, a ZEP product. I've used it before to get stain off dors, paint off chairs, etc. It has done well in the past, and seems to have helped tremendously here.

Another shot, showing the dropcloth - Thanks Rusty!!!

While I had the stripper out I stripped the shifter console. Since I have veneer on the way, and this is pretty cracked, I may bookmatch and replace the veneer.

These don't really do it justice, I'll have to learn how to do good camera shots. A photographer I ain't.

What I don't have is a shot of the dent on the hood - I hammered it out. I think I finally have the hang of the hammer & dolly.

Great Service Testimonial

2007-07-24T09:52:00.000-06:00

Just like I bitched about what I considered piss-poor service a few posts back, I now get to glow about a good guy. Rusty Connell, at http://buymbparts.com/, is one of the nicest guys I've dealt with in dealing with parts and information. When you go to his web site, if he is online he does have a link to chat if he is there. On the telephone, he is pleasant, knowledgeable, and pretty doggone funny. He even laughs at customer jokes. Please buy from him, whatever you can.

The work is coming at me fast

2007-07-24T09:43:00.001-06:00

OK - the weekend was sort of a bust, but, I did get the radiator drain plug out. Once I drilled thru the plug, all sorts of nasty water came out. I literally stripped the head off the plastic plug - but I don't think I actually did it.

Several flushes with pure water yielded even more gunk out of the engine. Once the plug is in, we'll flush with some vinegar or mild citric flush material before fully operating. But, the engine needs to start. I can run for a minute or two with the radiator not full, and a plug of sorts in the bottom of the radiator. I wonder if I put Pig Putty in there if I would be able to get it out later - I may try. It is fun.

Anyway, Bonnie is now up on the ramps in the garage, awaiting some parts. Those are:

Radiator drain plug - Vendor A
DIY DVD on AC Repair - Vendor A
Fuel Filter Kit - Vendor A
Automatic Transmission Bushing Kit - Vendor A
Air Cleaner Rubber Mounts - Vendor A
A/C Belt - Turbo - Vendor A
Thermo Vacuum Switch - Vendor A
Rubber Pieces for Thermo Vacuum Switch - Vendor A
Right side mirror - Vendor B
Left door seat switch - Vendor B
Rear vent window glass - Vendor B
Ignition Switch - Vendor C
Hood Pad - Vendor C
Zebrawood 1/16" wood veneer - Vendor D
Veneer Tape - Vendor D

Other things I will need:

Windshield - found
Left driver door window motor - looking
Antenna motor/assembly - working over
Fix sprung door - found vendor

I pulled out the interior carpets, and the padding is abysmal. The back seat also had some wasp nests in it. I have pulled out the shifter panel, and it needs to be refinished. I'll strip that sucker, and redo. My son's video camera is sent for repair, so we'll have to upload from an analog camera. Old School, kind of like Paul Teutel, Sr.

I'll also fill in the vendor A - D later. I had a real nice talk with Rusty at www.buymbparts.com. Will give them a whole write - up as well.

Mixed results

2007-07-18T22:32:00.001-06:00

Limited results - the radiator drain plug sheared. Now, we do need a new one.

These are the connections by the master cylinder

This is the vacuum actuator referred to as S47, out of the driver's side door. It does not look like it has a vacuum hose connection. There was also not a vacuum connection in the door panel. We'll try to get teh video camera to display.

Here once again is the infamous wiper assembly. I think we'll trim down the grommet, and weld/braze/solder a washer onto there. This should make it hold.

This we found near the transmission. I had seen it before, but wanted to get a picture before we knocked it off.

Here's the new right hand turn signal, courtesy of Clint at Rolling Hills Farms Collectibles, and his Ebay store.

Here is the insides of the antenna mechanism. Looks like a little corrosion has taken place.

The inside of the tachometer assembly.

The AC compressor - belt is totally off, and the compressor does not turn. I think the mystery electrical connection hooks up here.

Another look inside the powered antenna.

This is a side view of the shifter connection to the transmission. It is very loose. I also did not see the vacuum switch I was looking for, plus the limit switch interlocking the starter.

A punchlist will be constructed in the next couple of days. There's a boy anxious to drive. We did find a good price on a windshield, courtesy of a reference from the new Firestone dealer in Friendswood. We are also doing some wire brushing to clean up rust spots, as well as stabilizing rust in places. I will also have to pull the dash components.

The weekend activities

2007-07-18T07:55:00.000-06:00

Got the right turn light assembly and some other parts this week. I'll install it today. The back vent window, the right mirror, and the driver's seat switch are on the way. I got the manual I ordered in the previous post. Now I must get her started, and able to be moved so I can get the passenger door situation unscrewed. Then, make sure the driver's window rolls down, and up, then a windshield. I'm getting a "large" order ready to place for neat stuff at http://www.dieselgiant.com. That will be to get the engine purring like a, well, a diesel.
The manual I got was somewhat helpful, but I overpaid for it.
Next, the bondo chronicles.

For those about to rebuild, we salute you

2007-07-13T08:58:00.000-06:00

A picture is worth a thousand words. So, here's a picture of the 617 diesel engine. This looks way cool when blown up. If you want a copy that is unredacted - email me.

A bad experience with a vendor

2007-07-10T08:21:00.000-06:00

Most folks I have talked to to get parts and manuals have been extremely nice and helpful. However, yesterday I got one who was not. I found this neat manual called "Why Won't My Diesel Start? - Diagnostic Manual" by Kent Bergsma. It is from http://mercedessource.com/. I initially bought it to be able to do some serious troubleshooting on Bonnie, as we had washed the engine with petroleum distillate based engine cleaner, and disintegrated the vacuum connections. I got a lot of help from Russell at http://www.dieselgiant.com/, who gave me all sorts of advice, even though I had not ordered the first thing from him. However, the folks at mercedessource.com indicated the manual was available for pdf download on their web site. I went to order, and a price for postage showed up. I made the assumption that they would be shipping me a hardcopy manual as well. So, I entered my credit card number, and all, and proceeded to try and find how I could download the pdf. When I could not, I sent a message via their contact us info, as well as called. I at least received a call back, but the lady on the other end of the telephone promptly informed me that they no longer did pdf's, that the email filters regarded their download sites as spam, etc. She also did not want to email me the pdf. Being an IT sort in my normal day job, I asked what kept them from getting past the spam filters. She did not know. I informed her that her web pages were still showing pdf download capability. She apologized, unconvincingly. I then floated the idea that I needed the manual, and what could she do to get it to me in a couple of days. She didn't get the hint or miss a beat, flatly informing me that Fedex second day would cost me about 20 bucks.

Normally I'm a believer that if you don't have something good to say about someone, then keep silent. However, one day I hope to have a number of readers of this blog, and I think I have some fiduciary responsibility to warn readers about places to stay away from. Good service should be noted. Piss poor service, especially among the fraternity of 1980's Mercedes owners, should be called out as well.

Stupid

2007-07-08T17:59:00.000-06:00

The mirror is mounted

The external side needs to be polished, but it is on. I've found one for the right side, as well as a vent window. But some screwups have occurred.

Here is the driver's side seat control. I thought I would take it apart, but not so good.

Here's the EGR valve. I think the cleanup last weekend deteriorated the rubber mounts for the vacuum system connections.

The ball connection for the windshield wiper assembly. It needs to come off.

Another vacuum system screwup.

Victory is ours

2007-06-29T21:15:00.000-06:00

She started, got out of the garage, and backed back in. She was smoky, and smelled like diesel. We did have to use some starter fluid. I think the trick was pushing the gear shift into park. That one let it turn over. It ran good, and got a lot of cobwebs out. We did get one of the back tires off, and replaced it with a wheel done at Discount Tire.
There's still some work to do on the doors, and some examination of lighting. The blowers for the AC worked. .
This is the underside of the windshield wiper. I think I can remove the ball headed bolt, and maybve get a snap ring underneath the fixture. I talked to another location today, and they wanted $89 for it. Stupid.

This was the engine well. Had the old shop vac in there, to get all of the glass out. It did well.

This dent in the hood needs bondo, like the bullet hole in the trunk.

This is the passenger door. Uugh. Needs lots of work.

Victory of sorts

2007-06-29T07:04:00.000-06:00

Well, last night we had a victory, of sorts. We actually got the engine to turn over. I thought it had something to do with the seat belt. I think now it is to do with the after-market alarm switch that is in the car. I think I depressed the switch on the underneath of the steering column to get it started. I'll get Charles to try that out. ANyway, we had the car starting, and thought it was out of fuel. We left, and went to a convenience store that had diesel. COming back, the engine would not even turn over.

I also sprayed WD-40 on the piece that will need to come off for the windshield wiper assembly. I got an estimate yesterday of $700 for that assembly. The ball joint is not sold separately. I guess I'll try my hand at engineering a new fixture.

Progress

2007-06-25T21:15:00.000-06:00

Well, this past weekend we got tires. There was a birthday involved. Imagine receving tires for your birthday, but that's what was involved. One was mounted, and the others need to be done. Also got the R&R switch out. I don't know why it is called the R&R switch, but we got the steering wheel out, as well as the lower panel.

We also got the starter motor to turn over. I think we need a new ignition switch. I'll pull the old one out to see if it can be refurbished. I think I can find instructions.

Here's a few pictures.

This door has some repair work to be done. We've gotten the windshield out, and we have the Mercedes shop manual, which has come in handy. It is just scanned pages, but it is handier than the Haynes manual. I have not seen a Haynes manual for the 126 series Mercedes of that vintage. This door does not close properly. It did at first, but the door got bent back when pushing into the garage. We did get the oil changed this weekend. 8 quarts of 15W40, and a new air filter inthe turbocharger. Next is to troubleshoot the ignition switch.

Plans for tonight

2007-06-14T12:50:00.000-06:00

We didn't get to do anything last night, as it was raining. Since it was raining, we couldn't open the garage. I also did not feel well after an entire day in a budget planning meeting at my day job. So, tonight we will crank it up and get it up on jack stands. This will help. The son is picking up other jobs here and there, and will be able to help with expenses. We did get a battery the other night, but we will need to get a battery tray. We're picking up a little momentum on parts locating. We're finding different stops for different items that we need. The most unbelievable part thus uncovered as far as expense is the right rear vent window. It costs as much if not more than the front windshield. Don’t know why. I guess we will get a little cardboard, and make a template, then put in some Plexiglas or laminated glass.

Dry Ice for shrinking dents

2007-06-13T07:42:00.001-06:00

Ice Express

8257 Gulf Fwy, Houston, TX (713) 941-7733

Ice Express

713-941-7733 ...

Last night's activity

2007-06-13T06:43:00.001-06:00

Well, last night we installed a battery. The battery tray is a bit rusted out, but we got it in so we can start diagnosing electrical situations. I also used some compressed air to get dents out, using the heat gun at first, and it is actually working. We'll get video tonight.

Starting

2007-06-13T06:35:00.000-06:00

We'll use this reference article tonight, to try to get Bonnie to turn over.

Starter Troubleshooting
This seems to be a much-requested procedure, so I've added it to my list of technical articles.
The situation here is that your car won't start. You turn the key to start, and you get nothing. This procedure is only for those times when the starter doesn't even try to crank the engine. You turn the key and you get nothing or maybe a click and some dimming of the idiot lights.
Here's the troubleshooting procedure for you.
Your first goal is to determine the state of charge of your battery. Turn your headlights on and see how bright they are. If they are of normal brightness then you are probably OK. If you have a voltmeter, put it across the terminals of the battery. A fully charged battery will read around 12.5 volts, a dead battery will be less than say 11.8 volts. If your battery is dead, charge it and then proceed to the next step.
Next you want to find out if your ignition switch is sending power to the solenoid. A preliminary check for this is if your idiot lights dim when you turn the key to start, that's a good indicator that the ignition switch is functioning properly. To check for sure, get under the car and disconnect from the solenoid the wire that comes from the ignition switch. It connects to a push-on spade connector on the solenoid. Fuel-injected cars have two spade connectors on the solenoid. In that case, the ignition switch wire will be the heavier of the two wires. Disconnect the wire, then use your voltmeter to check for 12v at that wire. Put the positive lead to the wire and ground the negative lead, then have your helper turn the key to start. When your helper does this, you should read 12v at the wire. If not, suspect a defective ignition switch or a break in the wiring (or disconnected) wire between the battery and ignition switch or ignition switch and starter. Repair and try again. If you do have power at that wire, move on to the next step.
Next you want to see if the problem lies in the starter motor itself. Looking at the back of the solenoid, you will see two big post electrical connectors. What you want to do here (TRANSMISSION IN NEUTRAL -- PARKING BRAKE ON!!!!!!!!!!!!!) is grab a big screwdriver or a pair of insulated pliers. Touch only the plastic or rubber handle. You want to take this tool and short across the two big post terminals. Be prepared for some sparks, but hold the tool up there until you make a good connection. What you are doing here is connecting the battery directly to the starter motor, WITHOUT engaging the solenoid. So what should happen is that the starter motor will spin but will not crank the engine. It should sound like a regular electric motor, no gravelly or strange noises. If it does not spin or sounds really bad, have it rebuilt. If it works like it's supposed to, the motor is good so move on to the next step.
OK, you're now starting to run out of possible problems! The next test is to see if the solenoid is working. Here's how this goes. First, TRANSMISSION IN NEUTRAL -- PARKING BRAKE ON!!!!!!!. Look at the back of the solenoid. There are the two big post terminals you just played with. Look at the one on the right. You will see that there is simply a short heavy braided wire attached to it that runs down into the starter motor. What you want to do here is spike the positive lead of your voltmeter into this braided wire and ground the negative lead. Then have your helper turn the key to start. When your helper does this, you should hear a clunk and measure 12v with your voltmeter (additionally, the engine should be cranking as this happens). If you do not measure 12v, your solenoid is not activating and is not sending power to the starter motor. I had a case on my van where the solenoid would clunk but I was only measuring 1.5 volts at that braided wire, and the starter motor was not turning. I had the solenoid rebuilt at a shop and that solved the problem.
What you can also do to further test the solenoid is to remove the wire from the ignition switch from the solenoid. TRANSMISSION IN NEUTRAL -- PARKING BRAKE ON!!!!!!!. Take your screwdriver or insulated pliers and short the big post with all the wires to it to the terminal on the solenoid where the ignition switch wire plugged in. This will bypass the ignition switch and send full battery current directly to the solenoid. This should make the solenoid kick in and the engine should crank. If it cranks this way but not when you do the test in the paragraph above, then your solenoid works but it's either sticky or you have a big voltage drop when going through the ignition switch, possibly a dead ignition switch. The preceding parts of this test should have identified a bad ignition switch already, so if you've gotten this far and it works when you short the solenoid directly to battery power, you likely just have an old stick solenoid that needs a lot more current to activate than it's getting from the ignition switch. See below for your options.
If you do not measure 12v at the braided wire as above, then there are two possible situations. First is that you have the famous VW hot-start sticky solenoid problem. What you should do (and I recommend this as a first remedy to anyone who is experiencing the above problem) is to wire a relay into the circuit. The circuit is already marginal due to the lack of a relay from the factory and the long wiring path. Age and temperature of the wires serves to further degrade the situation. You can wire a relay into the system and starting reliability will be greatly improved. See my relay installation article for instructions.
If, after wiring in the relay, your situation does not improve, then you have to face the music -- your solenoid is toast. Remove the starter and have the solenoid rebuilt -- if your starter motor tests fine and you are short on cash, you may wish to just have the solenoid rebuilt, as I did. I took it to a local automotive electrical rebuilder and that solved my problem. Or you can go whole hog and exchange your starter/solenoid assembly for a rebuilt model bought at a parts store. This, however, can be quite expensive.
And that should do it, that's a fairly good troubleshooting procedure that ought to tell you where you stand and what you need to fix.
Sean BartnikApril 6, 1998

The first night

2007-06-11T21:44:00.001-06:00

Well, we got the drivers side door off, and the busted windshield out. There's a lot of glass al over, but also a lot of satisfaction. Video to follow.

One of the first repairs

2007-06-10T17:45:00.001-06:00

This may be the first repair on Bonnie. This is a bullet hole in the trunk. We'll have to sand this one down, and fill with Bondo. It will be our first Bondo repair, but probably not our last.

The new blog

2007-06-10T17:31:00.000-06:00

Please join my son and I as we begin our new adventure, in refurbishing a 1983 Mercedes 300SD Turbo. There's a lot we have to learn, and there will be a lot of frustration along the way. He has tentatively named it "Bonnie", in honor of the nurse Bonnie from "Pulp Fiction". We hope that we don't get hammered with any licensing fees, as, hey, we don't have a lot of money. All we can do is hope Quentin Tarantino will appreciate us respecting his artwork, and his inspiration. Other choices were, "Christine", which was heavily negged, and "Janice", after Janice Joplin. But, Bonnie seems to be the choice for now.

We found this car on Ebay, and picked it up in a field near Waller, TX. The tires are cut, the windshield is busted, but hey, we've got a clear title. Lots to do, and lots to buy.