Diesel Engine Repair

Diesel injector removal and replacement kit for all 4 and 5 cylinder 220D 240D 300D 300CD 300TD 300SD models from 1970 to 1985. Kit includes the following:

* 1/2" DriveTorque wrench for setting proper specs upon re-installation

* diesel injector socket to remove and replace injectors

* (5) new heat shield washers

* pick tool to remove old injector heat shield washers

* 2 Meters of new OE braided fuel injector return line

* new injector end plug

*steel bristle brush, gloves and Illustrated instructions on procedure.

Brand new aftermarket molded expansion tank to radiator Hose. Fits all 126 300SD models.

This is the new factory genuine transmission vacuum modulator valve with adjustment key and cap. Failure of this part can lead to harsh or jerking shifts and in some cases prevent the transmission from shifting into 4th gear. There are other things that can cause problems with poor shifting, so there is no guarantee this new part will fix them. But due to the cost and ease of installation this is a good place to start. Be sure to confirm you existing modulator is the same color before ordering.

This is the new factory genuine transmission vacuum modulator valve with adjustment key and cap. Failure of this part can lead to harsh or jerking shifts and in some cases prevent the transmission from shifting into 4th gear. There are other things that can cause problems with poor shifting, so there is no guarantee this new part will fix them. But due to the cost and ease of installation this is a good place to start.

I have never been impressed with the rubber vacuum hose found on older Mercedes diesels. I don't think the engineers ever anticipated how much abuse or how long these hoses would need to last! Over the years I have seen way too many vacuum related problems lead back to a failed hose connector or short hose length. The combination of high heat generated in the engine compartment as well as both internal and external engine oil contamination are the chief causes of its early demise.

This rubber mount is often torn up, oil soaked or just plain missing. It sits right behind the center of the oil pan on a number of models listed above. I have often see the entire assembly removed. Check first to see if your engine has one before ordering. Its intended purpose is to minimize engine torque roll during acceleration and reduce harsh engine shake.

Here are the correct size metric nuts with built in shoulder washer. If you drop these in behind the injection pump you may never find them. When doing glow plug service it is always a good idea to have some spare nuts on hand. New Bosch glow plugs do not come with new nuts. You can always use your old ones - provided you do not lose them! Shipped as a set of 10 packaged in a zip lock bag.

Brand new Glow plug relay. Fits only 1986 to 1987 300SDL and 1987 300D 300TD models.

This o-ring has to be tough enough to handle the high heat at the injection pump. If you see oil leaks around the area of the rack damper (located on bottom at rear of injection pump) then replace this o-ring. Also recommend when replacing the rack damper with the upgraded bolt. O-ring is now included with our rack damper bolts. To order a new adjusting bolt CLICK HERE.

 

Location of o-ring on bolt:

 

If you are planning to install new glow plugs in your early 603 engine, it is essential that you ream the carbon out of the holes to prevent premature failure of your new plugs - especially since it is so hard to get to these plugs! If you have not done the job before, it can be very frustrating trying to figure out how to even get to the glow plugs. Our DIY manual will guide you step by step through the replacement process. These items are available separately, but we are offering this combined kit for a savings of approximately $18 off the sum total of the individual prices. PLEASE NOTE: This kit will not work in the 1990 to 1993 350SD or 350SDL. You will need to order the glow plugs and reamer separately ( use search box).

Included in this kit:

Looking for better staring performance? This new pre-glow relay will work on all later 123 Chassis 240D (1981-1983 ONLY), 123 Chassis 300D 300TD 300CD Turbo models(1981 to 1985 ONLY),  and 126 chassis 300SD Turbo(1981 to 1985) that utilize pencil glow plugs. Cover not included. (Does not work with the 116 chassis 300SD or ANY 1980 models).

If you own an early 5 cylinder non-turbo diesel then this is a must have diesel engine kit! This glow plug upgrade will do three things that will put a smile on your face: 1. Your engine will start faster and cold idle smoother. 2. Your glow plugs will last longer. 3. If you should burn out one or two glow plugs your engine (if healthy) will still start! If you have ever been stranded with bad glow plugs before you know the frustration. This kit will allow you to throw away your old series style glow plugs forever and replace them with the more efficient pencil style parallel glow plugs used in the newer diesels. ONLY FITS THE FOLLOWING: 115 and 123 chassis 5 cylinder non-turbo 300D Diesel engines from 1975 to 1979.

The complete kit includes the following:

If you own an early 123 4 cylinder diesel then this is a must have diesel engine kit! This glow plug upgrade will do three things that will put a smile on your face: 1. Your engine will start faster and cold idle smoother. 2. Your glow plugs will last longer. 3. If you should burn out one or two glow plugs your engine (if healthy) will still start! 

If you have ever been stranded with bad glow plugs before you know the frustration. This kit will allow you to throw away your old series style glow plugs and replace them with the more efficient pencil style parallel glow plugs used in the newer diesels. You will also receive an installation manual that contains step-by-step instructions with photos to help you to do the conversion yourself.

New nylon fan replacement. Only install on a fan clutch that originally had a nylon fan ( not an aluminum one). Shows up primarily on 1984 and 1985 models.

Brand new Valve adjusting LOCKING nut. Sold Individually.

Rebuilt 65 amp alternator without pulley. Includes fan and voltage regulator. You will need to install the pulley from your existing alternator. No Core charge. No hassle trying to have to ship back your old one. If the commutator rings are severely worn and grooved a new voltage regulator may fix the problem but not long term. Plan to replace the alternator.

Original exact tanks are no longer available. For these early models mentioned above you must purchase the later model tank that has an extra side port for the tank level indicator. This port is not used on the early models so you must purchase a special plug to close off that hole. That can be a hassle if missed when you order and I guarantee if you don't have the right tool and purchase these parts separately you may never get the plug in properly without losing your cool!

These are direct replacement nozzles for your factory Bosch Fuel Injectors. You can replace just the nozzle for better fuel economy, more power, easier starts, and less exhaust smoke.

12 month warranty provided on Monark Nozzles when all assembly precautions are followed (as detailed in included instructions).

This kit is for replacing the bushings associated with the engine shock. Sold Individually.

This rubber ring fits in the cap of the engine fuel filter. Does not come with most replacement filters. Should be replaced every 3rd filter change unless you seal is damaged during service.

Brand new 5 Cylinder Head gasket, for all 115 116 123 126 Chassis turbo and non turbo engines.

Fits all 110 111 113 108 107 116 114 115 123 126 201 124 129 140 early 60's to late 90's

We finally sourced a nice replacement gas cap for the older model Mercedes. It is not genuine but this one is even better than the original as it has a larger area to grip and more torque to turn with. You will also love how this feels on your hand on a cold day! Great grip! Smooth and Easy to Twist

These washers are used under the four nuts that hold the valve cover securely to the cylinder head. They help to prevent the over tightening of the valve cover as well as prevent the nut from loosening up. They also keep the nut from gouging the metal out of the valve cover. On most engines these special wave washers have long since been lost. Here is a set of 8 so you will have spares when you drop one down into the engine compartment!

This is a common oil leak area on the 300SD. The gasket fits between the oil filter housing and the plate that mounts the oil pressure sending unit. This is a genuine OE gasket.

Excellent air cleaner housing. No cracks, good cap stud and threads,and all side clips. No dent damage. Does not include wing nut. No air filter included.