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Diesel Engine Repair

Mercedes Diesel Automatic Transmission Peak Performance Tuning Manual by Kent Bergsma

Covers ALL Diesel Automatics from 1969-1985 220D 240D 300D 300CD 300TD 300SD

Item: MRM-TRANSTUNE
$32.95
61x Diesel Automatic Transmission Tuning Manual
Lets face it! Diesel automatic transmissions can be troublesome, particularly those models that use vacuum to control shifts. This is largely due to the fact that diesel engines don't produce vacuum naturally. It has to be artificially manufactured. This is what makes diesel transmission tuning difficult. The numerous vacuum and pressure controls that were added to make it shift properly can create all kinds of problems when they fail or get out of adjustment.The big challenge in writing the manual was to clearly explain how to get all these controls working in harmony for the transmission to operate at peak efficiency.

Mercedes 616 617 Diesel Shutoff Valve Adjustment and Leak Fix Kit

1977 to 1985 all 240D 300D 300CD 300TD and 300SD only

Item: DSL-COMDSVAK
$10.95
616 617 Diesel Shutoff Valve Adjustment and Leak Fix Kit

If your shut off valve is leaking oil or is not shutting off quickly (even with a good valve and proper vacuum applied to it) you may need to remove it for repair. You can adjust its travel with the items included in this kit. Comes with 2 new gaskets, proper gasket sealant and instructions for adjustment. Comes with instructions on how to remove and replace the valve but that is done is readily done by removing the four bolts that hold the valve to the back of the injection pump.

CLICK HERE to view the new and used fuel shutoff valves we sell.

CLICK HERE to order more gasket sealant

Mercedes Monark Diesel Fuel Injector Nozzles-Best Engine Performance Upgrade

Of all the upgrades for diesel engines that we offer on this site, I believe changing over to Monark injector nozzles will give you more performance improvements for the money that any other single product. From our own diesels to the glowing reports we hear from our customers - you may have a hard time believing just how true this claim is until you experience it first hand! And Monark nozzles are probably the last of a breed. Yes, they are still manufactured in Germany...

Mercedes 5 Cyl 617 Diesel Engine Fuel Injector DIY Rebuild Kit - NOZZLES SOLD OUT FEB 2012

For 300D 300CD 300TD 300SD 1975 to 1985

Item: DSL-COM617DIRK
$315.00
This item is currently Sold Out.

If you have been reluctant to overhaul your worn and inefficient Bosch fuel injector nozzles because the job is too difficult or too costly then think again! For approximately the same cost as rebuilt Bosch fuel injectors you can purchase this kit to rebuild them yourself in your garage and get better performance to boot! Works on all 617 engines 300D, 300CD, 300TD and 300SD from 1975 to 1985.

Mercedes Diesel Fuel Injector Balance Pressure Tester - Yes, You Can Do It Yourself!

For all MBZ diesel engines 1950 to 1993

Item: TUL-COMDIPT
$189.50

You are looking at the worlds first production diesel mechanical fuel injector bench tester available in the U.S. for under $200. These are built at the Mercedessource shop to control quality and production demands. This bench mount pop tester will allow you to economically test the spray pattern and fine tune (balance) your fuel injectors at home. With the injector fitting included it will work on all Mercedes diesels from the early 1960s up to 1993. This includes chassis 110, 115, 116, 123, 126, 201 and 124 and models 200D 220D 240D 300D 300CD 300TD 190D 300SD 300SDL 350SD.

Mercedes 617 Turbo Diesel Engine Anti Rattle Kit

1978 to 1985 TURBO 300D 300CD 300TD 300SD with air filter housing mounted on engine

Item: DSL-123ARK
$26.50
300D 300TD 300CD 300SD Turbo Diesel Engine Anti Rattle Kit

Works only on the 5 cylinder turbo engine from 1978 to 1985 (116, 123, 126 chassis). 300D 300TD 300CD 300SD. Does not work on some 1985 models with trap oxidizer (air cleaner mounted off the engine). If you own or have owned a 116, 123, or 126 with a 617 turbo diesel engine for any length of time you are probably very aware of the air cleaner shake and rattle problem (except 1985 models with trap oxidizer). Rubber mounts loosen up or tear and the mounting brackets seem to break way too often. With this kit and instructions I hope to help you eliminate or at least drastically curtain this common problem. After working on literally hundreds of these engines I have found that just replacing the bracket and the three rubber mounts is not the answer.

Mercedes 603 300D 300TD 300SDL Valve stem seal set

Fits 6 cylinder diesels from 1986 to 1987

Item: DSL-603VSS
$22.50

Complete valve stem seal set for the 603 engine.

Mercedes Maintenance Sealant and Adhesive Survival Kit

These are the top five for your work bench

Item: SEALANT-COMBO
$19.99

Kent is often asked what are the most important SEALANTS AND ADESIVES to have around for your Benz. These are his top 5 picks. This kit includes the following 5 products:

Mercedes Maintenance Metric Combination Wrench Set - Kent's Favorite - SPECIAL PURCHASE

Made by Allen Industrial Tools - Only $10 with any order of $75 or more

Item: TUL-SPECIALCWS
$16.95
$10.00 On Sale!
This item is currently Sold Out.

Here is what Kent says about these wrenches: " I am very picky about the "feel" and "fit" of my combination wrenches. Some are just too smooth and slippery, while others just don't feel good in your hands. Then their are those who have real thick heads that make it hard to get on close quarter nuts and bolts (like Kobalt). A lot of the real cheap wrenches don't fit tight on the heads, thus causing rounding off of the heads (like a lot of them)!!

Mercedes 50 AMP Glow Plug Circuit Strip Fuse - Sold Individually

For 1977 to 1983 240D

Item: ELT=240GCF
$1.80

50 amp fuses were used on most 123 240D diesel glow plug systems due to the lower amp draw. 80 amp fuses will also work but some may choose to go with original spec. Check the number on the center of the fuse you are currently using. It should read either 50 or 80.

Mercedes Late 60x (602 and 603) Diesel Prechamber Collar Nut Socket

Special Splined Socket Only - NO INSTRUCTIONS

Item: TUL-L60X-PCRS
$62.50

This is a special pre-chamber collar nut removal socket ONLY that works on the diesel engines in the 1990 to 1991 350SD 350SDL (126 chassis), 1990 to 1993 300D 2.5 (124 chassis), and 1992 to 1995 300SD / S350 (140 chassis).  This tool will only loosen and tighten the special nut holding the prechamber in the head. More is needed if you plan to remove a prechamber in the head.

WARNING: Removal of the prechamber is an intermediate to advanced D.I.Y job.  No instructions or additional support is provided.  Do not purchase this tool unless you are familiar with this procedure and the special precautions associated with it. 

Here is a summary of the steps required to perform this job:

Mercedes Late 60x (602 and 603) Diesel Prechamber Removal Fitting

Not a complete tool but it will allow you to make your own puller

Item: DSL-L60XPCT
$28.00

This is a special pre-chamber fitting ONLY that will allow you to make your own prechamber removal tool for the 1990 to 1991 350SD 350SDL (126 chassis), 1990 to 1993 300D 2.5 (124 chassis), and 1992 to 1995 300SD / S350 (140 chassis).  You will need to purchase a 5 lb slide hammer as shown here and then weld this fitting onto one of the threaded fittings that come with the slide hammer kit. Any auto machine shop can provide this service for you if you don't have your own welder. 

WARNING: This is an intermediate to advanced D.I.Y job.  No instructions or additional support is provided.  Do not purchase this tool unless you are familiar with this procedure and the special precautions associated with it. 

Mercedes Diesel Engine Fuel Injector Return Hose 2 Piece

Two short pieces for emergency - NOT ENOUGH TO DO COMPLETE ENGINE.

Item: DSL-INJHOSE2
$3.95

Carry these two pieces in your diesel for road side emergencies. Not uncommon for an injector return hose to fail when you are out on the road. This hose will fit most all Mercedes diesels from 1969 to 1995 that use rubber return hose connected to the fuel injectors 220D 240D 300D 300CD 300TD 300SD 190D 300SDL 350SD and 350SDL. NOT EXACT LENGTHS. One piece measures from 15 to 18 inches and the other piece will measure from 6 to 8 inches.

Mercedes Small Vacuum System Hose assortment

5 Misc pieces to be primarily used throughout vacuum system

Item: VACHOSE-5ASSORT
$3.75

5 pieces 11" to 16" long misc ends from our cutoff stock. From 1/8 inch to 3/16 inch diameter. These can be used on various vacuum connections. Maybe some small fuel hose included. Yes, Kent does use fuel hose on vacuum systems as it will not swell and rot like regular rubber vacuum hose.

PLEASE NOTE: Not to be used for diesel fuel injector fuel return hoses!!

Mercedes 116 123 Turbo Alternator belts - Set of (2)

Fits turbo diesel 1978 to 1980 300SD and 1981 to 1985 300DT, 300CDT, 300TDT (Turbo Models Only)

Item: DSL-COMABS2
$17.95

Brand new set of (2) Contitech Alternator Belts. Fits models listed above.

Mercedes Maintenance-3/8 Inch Drive Torque Wrench and Case - SALE!

Use around engine and engine compartment for smaller bolts and nuts

Item: TUL-3/8TORK
$29.75
$20.00 On Sale!
This item is currently Sold Out.

This is a very handy smaller torque wrench to have in your tool box. It will do fuel injectors but is not quite big enough to torque wheel lug bolts. Range is 5 to 80 foot pounds. To order a 1/2 drive torque wrench CLICK HERE.

Mercedes Maintenance-Heavy Duty Pick Tool Set

Item: TUL-HDPICK
$7.95
This item is currently Sold Out.

Nice set of heavy duty pick tools with rubberized handles. They have hardened steel tips which allow for more prying and twisting with less tendency to bend the tips.

Mercedes Maintenance-3/8 Inch Drive Long Magnetic Tip Extension

Item: TUL-MAGNETEXT
$12.95
Quality Tool. Use as a long extension on your 3/8 inch ratchet. The magnetic tip will help to hold the bolt into the socket. Or you can remove the socket pull out the telescoping tip and use it as a pickup magnet to get into hard to reach places. LIMITED SUPPLY.

Mercedes Engine Crank Rotation Ajustable Length 1/2 Inch Drive Ratchet Wrench

Rotate Engines on 220D 240D 300D 300CD 300TD 300SD 300SDL

Item: TUL-EXTRATCHET
$22.75

This is Kents new favorite ratchet wrench for turning engines over during service and repair. There are a number of maintenance procedures that require you rotate the engine over by hand. This would include timing chain replacement and timing, injection pump timing and replacement, valve stem seal replacement, valve guide rails and camshaft replacement, front crank seal replacement, transmission removal and replacement, or any other procedure that requires engine rotation.

Mercedes 601 602 603 102 103 104 Rear Engine Crankshaft Seal Replacement Kit

Change this seal anytime you remove the transmission!!! - Carefully check models covered listed in description

Item: DSLGEG-COMRCSRK
$38.95

Once an engine or transmission gets over 20 years old the seals start to fail and will eventually leak. Many times it's not from wear on the seal lip, but rather from age. I said this many times that age is the big killer when it comes to something made of rubber, plastic or any type of synthetic flexible material.

The rear crankshaft seal is one such problem area on older Mercedes gas and diesel engines. if you have one of the old 616 or 617 diesel engines it's very difficult to change the rear crank seal without removing engine from the car. But many other early models including all those diesels produced from 1986 onward have a replaceable rear crank seal that can be removed and replaced once the transmission is pulled out of the car.

Mercedes Happy 65th Birthday Kent!!

Thanks for all you have done for the Mercedes Benz community!

 

 

 

 

 

 

HAPPY BIRTHDAY KENT!

You are all these things and more to us Kent


 

 

 

 

Mercedes Enthusiast

 

 

 

 

 

 

 

Mercedes Source All Metal Pre-filter Repair and Parts Service Kit

New bowl and internal parts as shown to service the special metal filter we sell

Item: COMBU-REPKIT
$23.95

If you have purchased one of our all metal diesel prefilters the day may come when you need spare parts to service or repair your old filter. This kit includes the following:

  • New metal bowl with threaded rod
  • New o-ring to seal metal bowl to top housing
  • New seal at bottom of filter
  • New seal at top of filter
  • New metal filter

NO INSTRUCTIONS or additional fittings included. CLICK HERE TO VIEW OUR COMPLETE METAL FILTER KITS.

Mercedes Early Diesel Pre-chamber Removal Adapter Tool and Instructions

This is NOT a complete tool. You will need to weld it your slide hammer

Item: ADAPTER-SH
$29.95

If you already have or are willing to buy a 5 pound slide hammer, you can make your own diesel prechamber removal tool. Slide hammer action will allow you to PULL it from the cylinder head once you have removed the collar nut and the glow plug ( a collar nut removal tool is required. CLICK HERE to learn more). Complete instructions are included on how to remove and replace the pre chamber once you have welded this tool to your slide hammer (no instructions are sent on how to weld it to the hammer as most slide hammers are different).

Mercedes 603 6 Cylinder Diesel engine Serpentine Alternator Drive Belt

Fits 124 300D 300TD and 126 300SD 300SDL

Item: DSL-603ADSB
$29.75

Brand new alternator drive Serpentine belt for 6 cylinder Mercedes Diesel 603 Engine.

Mercedes 60x Injection Pump Stop Lever Shaft Leak Fix Repair KIT

For 5 and 6 cylinder diesels 1986 to 1995

Item: DSL-60XSSLEAK
$19.95

This is one of the more common oil leaks I see on the 602 (5 cylinder) and 603 (6 cylinder) diesel engines. In fact, I have seen it on almost every one of these engines I have worked on. It may not be a large leak, but there seems to always be oil wetness around and below the area of the emergency stop lever on the side of the injection pump. This applies to the 1986 to 1987 300SDL, the 1987 300D and 300TD, the 1987 to 1989 190D 2.5, the 1990 to 1993 300D 2.5, and the 1990 to 1994 350SD, 350SDL, 300SD, and S350.

 

Mercedes 617 123 Turbo Diesel Camshaft and Rocker Arm Assemblies

Fits all 1981 to 1985 5 CYLINDER turbo 300D 300TD 300CD

Item: 617CAM-DSLHV
$220.00

Very good used camshaft and rocker arm assemblies as shown. Check your camshaft for flat spots on the lobes when doing a valve adjustment. A common problem on high mileage engines and is not good if you find flat spots or severe scoring.

Mercedes 1990 to 1995 6 Cylinder Diesel Glow Plug Relay

For 126 chassis 350SD 350SDL and 140 Chassis 300SD and S350 ONLY in those years

Item: ELT-L603GRELAY
$112.80

New German made Glow Plug Relay for models and years listing. No instructions. Lists for $210.00

Mercedes 615 616 617 Diesel Engine Oil Pan and Vacuum Pump Housing Bolts x 10 - (New)

Fits most diesel oil pans and vacuum pumps 1969 to 1985 220D 240D 300D 300CD 300TD 300SD

Item: DSL-6PNBOLTS
$12.80

Set of ten (10) new short pan bolts with wave washers included. Will work on lower metal pan as well as vacuum pump housing. Common places for this type of hex bolt to round out. Sold in multiples of 10 only. Change quantity in your shopping cart if you need more.

Mercedes Late 60x (602 and 603) Diesel Prechamber Slide Hammer Puller

FEB 2012 NO LONGER AVAILABLE - Read end of description on how to make your own

Item: TUL-L60X-PULLER
$79.95
This item is currently Sold Out.
For 1990 to 1991 350SD 350SDL (126 chassis), 1990 to 1993 300D 2.5 (124 chassis), and 1992 to 1995 300SD / S350 (140 chassis). This is a pre-chamber removal tool ONLY. It does not include the multi-spline socket tool you will need to remove the collar nut. EXTRA slide hammer puller fittings are included as shown. These can be used for other types of jobs. NO INSTRUCTIONS included other than that which is described below: