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Old 11-06-2008, 09:06 AM
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Join Date: Sep 2008
Location: NJ
Posts: 75
Tear Down In Progress

I have been trying for over a month now to pick up a decent service manual on Ebay. I just bought my third stinker.

I am tearing down a 84 300sd motor to recondition and wondered while I continue to wait for a service manual, if I could get some help here so I can continue.

Removing the Injector pump from the block - Is there anything I need to know here? Parts to mark position for when reassembled? Anything going to fall out at me?

Disassembling the timing chain - Again is there a procedure I should be following?

Removing the Harmonic Balancer - Anything to beware of?

Like I said, a good service manual would cover all these issues. Thanks for any help.
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Old 11-06-2008, 11:38 AM
StaggerLee's Avatar
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Join Date: Apr 2007
Location: Where the climate suits my clothes(Seattle)
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The search function is helpful

This link may help. I searched on "Injection Pump Removal"

1981 300TD "The Green Lantern"
1980 300TD
1983 300D Euro "China Cat"
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Old 11-06-2008, 11:54 AM
Admiral-Third World Fleet
Join Date: Feb 2002
Location: Central FL
Posts: 3,068
The service manual for the W116 contains the OM617.950 and is available for your use at :

This is the earlier version of the OM617 used on the W116 300SD, but should be close enough to support a teardown. I would look for the correct OM617.952 manual when you start measuring and rebuilding as there may be subtle differences.

80 300SD (129k mi) 82 240D stick (193k mi)77 240D auto - stick to be (153k mi) 85 380SL (145k mi) 89 BMW 535i 82 Diesel Rabbit Pickup (374k mi) 91 Jetta IDI Diesel (155k mi) 81 VW Rabbit Convertible Diesel 70 Triumph Spitfire Mk III (63kmi)66 Triumph TR4a IRS (90k mi)67 Ford F-100 (??)
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Old 11-06-2008, 12:02 PM
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Join Date: Apr 2002
Location: NW WA
Posts: 6,285
Haynes has a pretty good general guide which can be handy.

1985 Euro 300TD 5 spd 220K
1985 Euro 240D 5 spd 130K
1979 240D 5 spd, 40K on engine rebuild
1994 Dodge/Cummins, 5 spd, 121K
1964 Allice Chalmers D15 tractor
2014 Kubota L3800 tractor
1964 VW bug

"Lifes too short to drive a boring car"
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Old 11-07-2008, 09:02 AM
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Location: NJ
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Thanks. That last link provided everything I was looking for.
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Old 11-07-2008, 11:54 AM
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Join Date: Mar 2006
Location: Sonoma Wine Country
Posts: 8,394
The factory CD-ROM ($19.99 from Mercedes) for the W123 cars covers the OM617.952 motor, which should be very similar to yours, no?

"Buster" in the '95

Our all-biodiesel family
1995 E300D (W124) . .239,000 miles My car
1996 E300D (W210) . .313,000 miles Wife's car
Santa Rosa population 170,685 (2012)
Total. . . . . . . . . . . . 722,685
"Oh lord won't you buy me a Mercedes Benz."
-- Janis Joplin, October 1, 1970
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Old 11-07-2008, 11:59 AM
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Location: Out in the Boonies of Hot, Dry, Dusty, Windy Nevada
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the Paul Drayton site is not available any more , he took it down a couple months ago.

looks like he has some therapy sessions you can take when the engine project starts getting complicated.

Look on E-Bay for paper manuals, they come up once in a while.

there were three HP ratings on the OM616...

1) Not much power
2) Even less power
3) Not nearly enough power!! 240D w/auto

Anyone that thinks a 240D is slow drives too fast.

80 240D Naturally Exasperated, 4-Spd 388k DD 150mph spedo 3:58 Diff

We are advised to NOT judge ALL Muslims by the actions of a few lunatics, but we are encouraged to judge ALL gun owners by the actions of a few lunatics. Funny how that works
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