Well, thanks to Bill Grissom's (and others) input, I got the shut off valve installed properly. Two days ago. And yesterday I installed the plastic washers in the shifter. So it starts in Park like designed and, when I turn the key off, the engine goes off too. Been driving it most of the day today and it seems to work.

Here are some comments and missteps to avoid in installing the shut off valve:

1. Tape or tie up the VAV. Unlike what DieselGiant said it will not lie on top of the oil cannister. It was in the way much of the time before I taped it up.

2. Do not forget to reuse the thick metal washer on the shut off valve. Use one fabric washer on either side of the metal washer. If you do not, the shut off valve will not tighten against the back of the injection pump. I forgot the first time.

3. Comment - I thought the bump on the bottom of the shut off valve would fit in the slot at the bottom of the injection pump snugly like a key. Not so. At least for me. I twisted the shut off valve back and forth (maybe half an inch or more) thinking I would feel it snap in and that would give me the proper orientation. Did not happen. Should have paid more attention to the orientation of the outside vaccum nipple on the old shut off valve before I removed it. Looked at the pics I took before starting the job and it was not quite perpendicular so I twisted the entire shut off valve just a bit off top dead center toward the drivers side. Just enough that it cleared the ALDA cover (which I had twisted 90 degrees so I could look inside); I believe straight up the shut off valve would have not allowed the ALDA cover to twist back in place because the cover has one hole which protrudes somewhat outside the ALDA cover frame.

4. With the ALDA cover twisted you can easily see that the arm of the new shut off valve is outside (nearer the front of the engine) the internal linkage and by applying vaccum to the nipple you can see that it will pull on the internal linkage. However you can twist the shut off valve quite a bit back and forth and orient the arm quite a bit even to the point that it misses the linkage. I assumed it was supposed to be about in the middle when it pulled back so that is where I left it. Was not sure that was right - especially since the bump on the bottom did not help with the orientation - and was concerned that it might not work right. But after buttoning it up, it worked fine. Engine turned off just right.

5. There is really enough room to work, especially if you use a Mityvac to pull in the arm of the old shut off valve to get it out. Fortunately my old valve held some vaccum and I got it out fine. Same with installing the new shut off valve. Pull the arm in with the Mityvac and it will angle in fine. Since the ALDA cover was twisted 90 degrees it was easy to to see that the arm went in right when the vac was released.

6. I found that DieselGiant was right that a rattlecan top would shut off air to the engine in case of a runaway engine. I misinterpreted what they called the turbo inlet. What you do is remove the smooth plastic (4-5 inch?) horseshoe shaped tube from the turbo and you find the turbo inlet. The top fits pretty well on the bottom inlet which goes to the turbo; it does not fit on the top inlet nor on the air cleaner inlet. Fortunately I did not have a runaway and I did not need it.

In all it took me four hours. I could do it again in probably one hour. Guess that is what you call a learning curve.

Thanks again to Bill Grissom and the others who provided invaluable input. The DieselGiant write up and pictures were also a great help.

I'm very glad you didn't have a run away. Extremely scary.

Good job!

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'84 190D 2.2 5MT (Red/Palomino) Current car. Love it!
'85 190D 2.2 Auto *Cali* (Blue/Blue) *sold*
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Not really a term that I had heard before. Ended up not being a problem.

I have swapped several stop valves and never removed the "ALDA cover". That does let you see exactly how the stop valve's bent end acts on the lever. If it goes in freely and you feel it hit something as you try to pull it out, you know the end is sitting in front of the internal lever, as it should. Kind of like fishing. I thought the vacuum tube is supposed to sit straight up. The valve's side bulge barely extends past the gaskets, but I think it goes into the IP's keyway as you tighten. I can probably swap a stop valve in 15 min, but my ratcheting box wrench set makes it much easier. Great for glow plugs too.

Good you figured out how to re-install the metal spacer w/ a gasket on each side. In your package, I did write a note, "Be sure to notice how the spacer ...". Anyway, I miss info too when working and sometimes have to redo steps. Let me know if that "made in India" stop valve lasts. Of the 8 I sold, nobody complained of a failure after 2 years and I did provide a 1 yr warranty on most. I was thinking of buying another batch from the surplus place, but recently ran across a site selling them for ~$65, so could hardly break even after shipping. Probably from the same factory. I wonder if the very expensive M-B branded ones come from the same place too. How many factories in the world do people think could be making these? I don't know if these stop valves are even M-B specific. Many of the Bosch diesel parts were used by other manufacturers, especially VW and smaller European manufacturers. The ones branded "MTS" some years back tended to leak. Could have just been a bad batch from the same place. I bought one on ebay that leaked. Cut it open and found the diaphragm was still good and it was just leaking at the outer crimp. I crimped it back together, put "flowable silicone" sealant around the gap and it then worked fine, so try that first if anyone has a leaker (auto parts, for windshield sealing, gasket sealant might also work).

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1984 & 1985 CA 300D's
1964 & 65 Mopar's - Valiant, Dart, Newport
1996 & 2002 Chrysler minivans

Yes, I thought the vacuum tube should have been straight up and neglected to look closer before I removed the original. It is just a bit off straight up now and is working fine - probably twenty times today.

Will keep an eye on it.

Glad to get my SD running again.

How many miles on the 'SD at this point? I seem to remember that you are the original owner...

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"Senior Luna, your sense of humor is still loco... but we love it, anyway." -rickymay ____ "Your sense of humor is still loco... " -MBeige ____ "Señor Luna, your sense of humor is quite järjetön" -Delibes

1982 300SD -- 211k, Texas car, tranny issues ____ 1979 240D 4-speed 234k -- turbo and tuned IP, third world taxi hot rod

2 Samuel 12:13: "David said to Nathan, “I have sinned against the Lord.” And Nathan said to David, “The Lord also has put away your sin; you shall not die."

261,077 as of 6:23 pm EST today. Yes, original owner.

Would you say you got your monies worth after 31 years of ownership?
I respect an original owner that can still find the charm behind these old machines after all these years.My first diesel was in 2003 ,an old 79 300td that after seeing how badly it was treated maintence wise was pleasantly surprised how sweetly the diesel motor sounded at 360k miles of road use behind it.I guess thats what sold you on the original walk up of opening the hood and hearing something like no other of its time.

All of my Land Rovers have forced me into love-hate relationships. I love them when they are performing properly but I know that tomorrow something will probably break. If you cannot work on them yourself, you are out of luck. They are incredible vehicles but do not trust them- ever.

The 300SD has been the best performing, most reliable, easiest to repair, and strongest dollar for dollar investment that I have ever enjoyed in a vehicle. I do not forsee any reason ever to get rid of it.

The Lexus is probably the best modern vehicle I have had and it is more fun to drive, gets better gas mileage, and may be just as reliable as the SD. But at some point I will get rid of the Lexus and buy another. I am sad that I cannot really work on it myself other than repairing the brakes - but then there is never anything wrong with it.

That said, I will probably still have the SD long after the Lexus is gone.

OK, here is the SD today. Washed and back on the road.

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Well, happy 35th anniversary! That really is a timeless car. I hope I can own mine half as long.

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"Senior Luna, your sense of humor is still loco... but we love it, anyway." -rickymay ____ "Your sense of humor is still loco... " -MBeige ____ "Señor Luna, your sense of humor is quite järjetön" -Delibes

1982 300SD -- 211k, Texas car, tranny issues ____ 1979 240D 4-speed 234k -- turbo and tuned IP, third world taxi hot rod

2 Samuel 12:13: "David said to Nathan, “I have sinned against the Lord.” And Nathan said to David, “The Lord also has put away your sin; you shall not die."

Yes. Good luck with yours