Im going to write up my thoughts here so that anyone with this sort of a car/engine or doing this sort of plan has a reference.
For the car, Id make the assumption that you'll lose a tire, and that you'll also damage your glass. I dont know how much extra space you have/want to have in the car (Ive reclined and slept in a w124 when car camping on road trips with my kids, and it isnt bad if you can get it all the way back), bu the stink and space of extra tires/spares (mounted or unmounted? Unmounted may be a better bet for space savings) would be a consideration.
I'm assuming that all fluids are replaced/baselined, all consumable parts are in fine shape (e.g., belts), etc. I would have your injectors pop tested and balanced by greazzer on peach parts. I can pm you his info. This way your injectors are enabling optimal combustion, and you’ll replace the soft return lines between the injectors too. I’m also assuming that your shocks are good, the ball joints are new(ish) and no suspension rubber is torn. Also check your cv joints for cracks - the only time a Mercedes stranded me was when a cv joint tore open in Tennessee and was too noisy to risk taking the ride home. Also check flex discs. And either swap your wastegate to a pressure actuated version, or verify that your egr/vacuum setup is correct and not leaking vacuum. What you don’t want is to lose boost because of the wastegate setup in the middle of nowhere. The OM602.96 series use a computer controlled, vacuum closed wastegate. Different from any other MB diesels of the time. I’m also assuming that your rear shocks are up for the weight. Seriously. I was quite surprised at the geometry when I took my 1991 300D to Cincinnati and back, filled on the way home with three extra car batteries, a bunch of food, luggage, baseball gear, etc.
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So for the car going kn a multi-thousand mile austere trip, Id want to have at minimum:
- Full size spare, mounted - depending upon age of your tires, maybe replace all five.
- Extra spare tire if needed (matching? Old pull-off? WM special?)
- Glass repair kit
- Jack - the MB jack may not be your favorite or most stable. A hydraulic jack is large and heavy, even if the HF 1.5 ton aluminum which is best in class.
- Breaker bar (more on this in the engine section) and 17mm (verify size) socket for lugs
- Cold weather fuel additive
- Cetane boost additive
- Short section of rubber vacuum hose
- Jumper cables
- Alternator voltage regulator
- blankets
- sun shade
- pillows
- gallon jugs of distilled water (good for drinking and radiator)
- 12v tire inflator. Some are really cheap/bad. Vlair 88P would be my pick, but the HD and HF cheaper are ok.
- Tire plug kit
- chock for the tire
- small board for jacking in loose soil on austere road
Other tools:
- Two screwdrivers - I like to have one of the cheap kind with the four bits that swap direction in the handle/shaft, and then a ratcheting one.
- decent multimeter with very fine probes
- I generally know my cars and so for most trips my ratchet set is just a 1/4” US made set with a long handle 1/4” drive Snap on ratchet and a wrench set.
I have a mess in my trunk, but this is what it looks like. It all fits in a Klein tools bag. You may want to bring at least a legit 3/8” drive set.
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For the engine:
- long 1/2 breaker bar with 27mm socket to turn the engine
- whatever tool removes your fan. All services related to belts, pullies, and tensioners require removal of the fan some of my OM60x engines use an 8mm Allen, one of them with a newer fan/clutch takes a female Torx socket. Verify your setup and the stack-up length before you leave!!!! The Allen’s are usually too long, most ratchet/socket setups are too deep too and can damage your fan!
- a pulley holder tool so you can remove the fan bolt - the $15 performance tool unit works great
- A spare belt. Continental contitech is the best bet. If yours hasn’t been replaced recently, get a new one, put it on, and bring the old one. Or vice-versa.
- Spare fuel filters - primary and secondary
- Some extra fuel line for the clear fuel filter, and a length of the smaller return hose
I think this is such a great trip. Chronicle it. You have to make a photo thread that shows the whole trip. I’m so excited for it!!!
Let me know if you want some visitors to come and work over the car in prep!!