Hi guys,

Thanks for the info so far. I've just read the new posts and I know what I'll be doing on my last day off. Gota love having old cars.

Questions to all:
How common is it to have a delivery spring fail in an IP?
Will removing the access panel on the side of the IP at the delivery valves cause anything to become in jeopardy of falling out of place?


I consider my self a decent DYIer but no expert on IPs. However, I've successfully completed the R&R of the delivery springs, seals and washers my other 5 cylinder w201. I've been tinkering with MB diesels for about 5 years and anything mechanical since I was 13. So I'm confident enough to attack most jobs, but experienced enough to know when I've reached my limits. So what I'm saying is don't hold back anything!

I'm going to give up on this, I've spent a day trying cranking/charging with no change. And still no fuel at the front injector.
The glowplugs are relatively new and the weather has been nice and warm here so the GPs probably aren't an issue.

__________________
'87 190d TURBO 200k
'84 190d 230k miles
'85 190d 107k miles
'88 190d 2.5 259k miles
'85 BMW E23 220k miles
'94 Chevy K3500 6.5L Turbo Diesel 232k miles

"Diesel Noise -- The Sound of Freedom"

One last quick check. Open return line at injection pump.Does fuel come out when you crank engine? If so there is enough fuel present in the pump under at least a little pressure to supply the number one element.

The other manageable possibilities as I think you have a more modern injection pump than the 123s use. The delivery valve is fouled and not seating by something.Could be a section of broken spring for example. Or the elements seals have failed letting the elements pressure as it builds up escape internally.

Other than those two things I expect it is beyond the average person to repair in the pump. So a good used pump is in order in my opinion at that point. At least they are available..

Very rare. I've never heard of it.


No. You won't see the delivery valves though, those are in the fuel circuit. Removing the cover allows you visibilty to the external parts which are lubed by engine oil.


Don't worry about the front injector. The engine should start & run even with one dead cylinder.


You have checked for voltage at the GP's, right? And checked the fuse on the GP relay?

All of the stuff I mentioned to check on the Fuel Injection Pump seldom happens (They represented things that I have seen happen to IPs when I used to work at a job where I rebuilt them that would result in no Fuel on one Element when everything else is OK).
I would check all of the normal issues first and leave the IP alone until you reach the point that you have eliminated everthing else.

The worst thing that can happen from removing the IP cover is that when you put it back on you might get a Oil leak there. This assumes that you did not do anything else but look inside.

It could be as barry said that for some reason you are simply not getting enough Fuel Supplied to the IP and it just happens #1 is higher than the rest and is not getting the Fuel Supply it needs.
No one has mentioned Fuel Supply Pressure from the Lift Pump Either.

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84 300D, 82 Volvo 244Gl Diesel

Okay, here's the latest update:

Still no change. I've cranked the engine/charged battery 20 times. Best was one time it sputtered for 4 seconds.

Could the delivery valve o-rings cause this problem w/o showing signs of fuel leakage? In my experience, when the DV seals are shot, the engine will be hard starting, but will still start.

@gsxr
You got me paranoid so I metered out the GPs and they seem okay. Can't reach one w/o removing intake; also I checked them at the relay. I think the GP relay is unique to this model; it certainly isn't the same as the non-turbo. YIKES, I hope not.

On this topic, could a bad temperature sensor or over-voltage relay or rpm sensor, etc. cause a no start. This turbo's IP is festooned with pods unlike my non-turbos.

@barry
Fuel is reaching the return.

My next step is to thoroughly clean the pump and surrounding area then remove the inspection cover. I won't get to it for a few days now as bad weather is scheduled for the next few days. I'm also considering replacing the delivery valve o-rings seals and springs as I did on my non-turbo. Made a big difference in performance.

I'll keep you posted on my progress.

THANKS AGAIN EVERYONE!

__________________
'87 190d TURBO 200k
'84 190d 230k miles
'85 190d 107k miles
'88 190d 2.5 259k miles
'85 BMW E23 220k miles
'94 Chevy K3500 6.5L Turbo Diesel 232k miles

"Diesel Noise -- The Sound of Freedom"

Is the way it is in the picture the correct way or the wrong way?