So I have an IP from an OM603 that doesn't appear to have been pulled properly. Looking in the 17mm hole on the side shows that the end of that cam inside is nowhere in sight, and thusly nowhere for the locking tool to lock on, etc. I'm wondering what you're supposed to do in this sort of situation.

it shouldn't be difficult to turn... just protect the splines.

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But how do you know where to turn it to... there's more than one point where the cam shows in the "window" (17mm bolt), it shows up repeatedly when turning the engine, not just at 15.

are you familiar with how the locking pin works?... and what it looks like?

do you see the notch where it should engage the locking pin.... there is only one.

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Well yeah, but when I rotate the engine the notch shows up at times other than 15 degrees.

really? You are saying there are at least 2 raised notches in one full rotation of the IP camshaft.

One final resort may be to use the spill timing method to determine when the #1 plunger begins to build pressure.

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I would assume that you rotate the IP until the locking pin can be inserted, then rotate the engine to 15 degrees after TDC of cylinder #1 and then install the IP. I admit I've never had the pleasure but that's what the FSM says.

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"Buster" in the '95

Our all-Diesel family
1996 E300D (W210) . .338,000 miles Wife's car
2005 E320 CDI . . 113,000 miles My car
Santa Rosa population 176,762 (2022)
Total. . . . . . . . . . . . 627,762
"Oh lord won't you buy me a Mercedes Benz."
-- Janis Joplin, October 1, 1970

Maybe I'm confused... I thought I saw it twice while rotating the engine. So all I have to do is turn it until locking tool can be put in?

NO DRINKING during IP work !!!!

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1980 240d ,

chain elongation, cam marks reference:
http://www.peachparts.com/shopforum/diesel-discussion/10414-help-i-need-check-stretch.html

http://www.peachparts.com/shopforum/diesel-discussion/305365-9-degrees-chain-stretch.html

evap fin cleaning:

http://www.peachparts.com/shopforum/diesel-discussion/156207-photo-step-step-post-showing-w123-evaporator-removal-1983-240d-1982-300td.html?highlight=evaporator

A/C thread

http://www.peachparts.com/shopforum/diesel-discussion/297462-c-recommendations-mb-vehicles.html

correct.

you will see 'metal' / 'parts of the camshaft' pass by the window twice in one full revolution.

But on one of those pieces of metal, there is a very thin notch running parallel with the IP camshaft.

This notch catches the pin ad there should only be one.

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From your description it sounds like you already have the IP on the engine (?). From what I've read, you have to install the locking pin on then IP, then rotate the engine to 15 degrees after TDC on cylinder #1, then install the IP. Remember to remove the locking pin before trying to turn the engine.

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"Buster" in the '95

Our all-Diesel family
1996 E300D (W210) . .338,000 miles Wife's car
2005 E320 CDI . . 113,000 miles My car
Santa Rosa population 176,762 (2022)
Total. . . . . . . . . . . . 627,762
"Oh lord won't you buy me a Mercedes Benz."
-- Janis Joplin, October 1, 1970

Guys, it is not the IP Camshaft you are looking at it is part of the IP Governor.

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84 300D, 82 Volvo 244Gl Diesel

Where did you get your FSM, Jeremy?

Hugh Sr
1984 190d (W201)

I have two: the two-CD-ROM FSM, which I bought from Mercedes when they still had some, and the paper FSM for the 602/603 engine, which I bought in August 2008 on eBay. The paper FSM is (literally) two inches thick, it's massive. The information for my comments on this thread came from the paper manual.

Jeremy

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"Buster" in the '95

Our all-Diesel family
1996 E300D (W210) . .338,000 miles Wife's car
2005 E320 CDI . . 113,000 miles My car
Santa Rosa population 176,762 (2022)
Total. . . . . . . . . . . . 627,762
"Oh lord won't you buy me a Mercedes Benz."
-- Janis Joplin, October 1, 1970