Time to put it back together!
 

I got all the parts I was looking for today!

Also, I may have discovered one of the causes for my failure; the TD and vacuum pump had no oil supply due to an incorrect/different spacer and washer on the intermediate shaft. The only oil they got was residual from the chain. I'll post pics and an explaination in a bit.

I ended up buying the injection pump and everything else for 60 bucks. The IP is identical to the one I currently have, except it doesnt have the electrical component on the side. I believe that is only for the EGR and ARV, both of which I've already disconnected. Both pumps are: PES5MW55/320RS16, but the one on my car has a "-1" suffix.

I got lucky on another thing too. When pulling the bushing off the P&P car, I saw a washer about the size of a quarter behind the bushing retaining bolt. I didn't remember one on my car, so when I got home, I took a magnet and swiped it around the timing device housing, and up came the washer. :D That could have been ugly.

Here's what I picked up at the P&P. What's different is that on my car, the rear spacer and washer were 2 separate parts. On the SD from the P&P, they were one piece.

What's significant is the distance from the back of the spacer/washer combination to the beginning of the opening that allows oil to flow. On the spacer with a seperate washer, the distance to the oil pathway is so long, that the hole that supplies the oil never reaches it. On the part I picked up today, that distance is much shorter, so the supply hole lies within the pathway. On the spacer, the indentation you see on the outside is equivalent to the one on the inside.

I don't know how these parts got on my car, but I doubt they were put there by the factory. It just doesn't make sense to make a pathway for oil flow, and then put the supply outside it. I believe this explains why I had a little rust on my timing device too. The device at the P&P was soaked in oil, and that car hadn't run in months at least. On mine, there was very little oil on it at all.

Even though it's different from what I pulled off my car, I think the one I picked up today is superior, and that's what I'll install.

Theo

well done, Theo. Now I know who to call for IP issues.

Is the new bolt to shaft a hollow one, or solid?

Solid. Identical to the one that was in the car, except that it's in one piece.:o


Thanks jt20. I really appreciate your offer to help me get the parts if the P&P didn't work out.

I'm pretty sure that on the 85's that electrical doohickey on the IP (rack position sensor I think) also has something to do with transmission shifts. Don't know what happens without it.

Ip
 

Yep the FSM states the diff between an early 2 piece and late 1 piece bushing...

Theo....You are now the aux shaft God....what an experience...!
If modern civilization ever collapses...you are going to be in demand....
Your determination is fantastic...the McGyver of pull-a-part....

I still think the sledgehammer and big whoop-chisel would have added a bit of whimsy to the removals.....

I did use the next best thing from the precision MB tool catalogue... bolt cutters. Took care of that chain in no time. :D

Thanks Yellit.

I've been looking at several threads that say it's only for the EGR and ARV. When (not if :)) my car is running again, I'll disconnect the connector and see what happens. I'd like to know that I have a spare IP that's compatible. If not, the extra IP will be handy for parts, and for 60 bucks, I can't complain.

Thanks

Done!
 

Got it put back together without too many hiccups, and it runs just like before. Thanks to yellit, jt20, Beagle, and everyone else who helped or followed along. WIll probably post some more details later, but I need to relax for a few.

thanks everyone

Theo

I've got to tip my hat to you for your tenacity and determination to see this disaster to a successful conclusion. Most would have abandoned the ship a long time ago.

You've done well!!

Theo.....One of the forums best...
 

Or should I say.... (Theo...AKA...Auxshaft Baron.....)

I must say that was a fine job....
A true measure of ability & diesel powered will...
Only a very few would have the gumption to pull that off...
Most excellent...!!!
This could qualify for its own TV reality series...

You did so much, for so long, with so little....
....That now...
You can do anything, anytime, with nothing...

Yellet, I'm not one of the best - you are.

Everything I did, I did for myself. You on the otherhand gave me tremendous support, advice, and encourgement, both in the thread and via PM's, out of shere generosity. That's what this forum is all about.

I'm forever in your debt. Thanks for everything!

Ip
 

Thanks for the kind post Theo....
I had that sinking feeling several times along this repair.....knowing exactly how you felt when hitting those possible ( ruined beyond repair surprises)....
When watching a thread, I see how little I really know compared to so many others here...all the different personalities and feedback along the repair path is really something to observe...

When I first started watching this forum I thought....these guys ought to be running the country ...amazing folks...!...they know how to get things done.....I needed them when I was a kid tearing apart broken lawnmowers....

There are so many talented helpful folks on this forum that it restores my hope for humanity....I think many of us identify with the struggles involved working on this stuff...no one really knows until they tear into something...

That sinking feeling of thinking ...Oh my God...I have just ruined my precious device beyond my resources to repair...

That is one of the worst feelings a fellow can have ....

But then because we somehow enjoy this stuff... we think alright..!..
A new challenge...I wonder if I can do this ?........and away we go....

Kudos to theo 3000
 

MAAAAAaaannnnn
You guys are awsome, the way you stuck with Theo all the way to the end on this thread,,,, that my friends is what makes this world a better
place to live, and i am seiously impressed with all of you.
Theo, as others have stated, you hung in there with tenacity that is uncommon,, GOOD JOB friend. and it is nice to see you had a happy end to this story.

Now, the reason i joined the forum: I had a similar fuel problem with a diesel turbo i bought at a towing impound auction, it was towed from a storage lot where it had rested unatended for over two years.

I towed it home, could "NOT" get it to start, entered a google search and found this forum.

All of you guys who had given your knowledge led me to what the problem was.

I simply followed your post and tips, removed some air from the new fuel filter and hand pumped the fuel, still would not start,,, sprayed a tiny amount of starting fluid into the intake, and Varoom,,, she started up and ran.

You guys are WAAAAAYYYY awesome for your talents and willingness to give it freely.

I THANK YOU for being here and being the kind people that you are.

AWESOME FORUM and thank you for this forum.

This 1982 Mercedes Benz 300D turbo can now be sold so i can pay the food bill:D

Its gotta be worth at least $600

Craigslist is next,,, so this sweety can go to a deserving new owner.

Once again,,, thank you guys.
Rog'

Ahhh........... the memories. That was a fun week.