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| autonovice Elite Veteran Date registered: Dec 2006 Location: New York City Vehicle(s): '05 G55K, '92 350GDT Posts: 684  | 24v to 12v conversion I know more and more ex military Gs are avail on the market. Unfortunately, these all come in 24v system. Replacement parts are expensive and rare if you can come across any. Fortunately, there are parts avail to turn your G to a 12v system. I had the luxury of doing it in a public parking garage over three nights, this past record snow winter! Yes it was cold and I only had hand tools and a LED flash light affixed to my forehead to work with. This is the inventory check list of 24v -> 12v parts needed. This is for a diesel setup. 1) head lights - 2 2) all around signal and indicator lights - 3) interior lights and map light - 4) front and rear wiper motors - 2 5) front and rear wiper washer motors - 2 6) alternator - 1 7) starter - 1 8) glow plugs - 5 9) glow plug relay - 1 10) front and rear wiper relays - 2 11) turn signal relay - 1 13) horn - 1 14) heater blower - 1 15) emergency flasher switch - 1 17) rpm tach - 1, expensive item! 18) kombi cockpit instrument - 1 19) light bulbs for locker and turn signals - 4 20) light bulb for rpm tach - 1 21) light bulbs for speedo, kombi cockpit instrument - 6 (or 7) Before disconnecting the battery, I ran thru the blinker, wiper replays and note their locations. Disconnect the battery. I started the conversion with the alternator. For 24v, MB added resistors to the D+ and B+ terminals. These are mounted on the body next to the altenator. Takes these out and throw them away. Trace the B+ terminal and note this to the 12v alt. The D+ terminal is insulated with ground wire mesh. Separate these and note the D+ to the 12v alternator also. Next is the glow plug relay. Remove the resistor and throw it away. Ensure to replace the same wire gauge to the new 12v relay. All other connectors should be the same. Starter swap could be really fun as it involved removing the oil filter tubes. What a mess! Easy swap but a real pain. You are now at a point of no return. Here I was in a public garage. I couldnt leave my G stranded for days and it would be difficult to get a tow truck into a garage 2nd floor if this project was a failure due to broken or stubborn parts. The next fun part is to replace the glow plugs. I got most tips from p3 Allister and AlanMcR DIY. Easier said than done. I didnt want to strip or break the glow plug as I had no room for failure. Having a magnetic pick up tool is a must. 3 out of 5 special nuts from the glow plug that secure the wire came off and I was lucky enough to recover them all. Reconnect your battery! First engine crank test. It worked. Dont worry about damaging any electrical parts, it wont blow out or burn. Start to replace exterior electrical parts. I replaced and tested as I went thru each major components. I would save the horn for last. Note: the blinker relay will need enough juice to run thru to get it to work. Dont bother testing it until u get all the bulbs and relay installed. For interior electrical parts, I replaced the relays, interior lights and saved the instrument panel swap for last. Well, I didnt mention the heater blower. Its a big project so I skipped it for now. The blower speed is now "super slow" and "slow" speed. I am ok with it. Tip: 1) This is a good time to apply dielectric grease to all electrical connections. 2) I balanced between buying new and used parts to save $$$ 3) Your 24v parts worth cash! Make sure you can work out a deal to trade in 24v for 12v parts with your source. Edited by autonovice 4/21/2011 6:44 PM | ||
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