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Old 04-29-2010, 11:41 PM
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Join Date: Apr 2010
Posts: 2
W115 240d Injection pump re-installation timing question.

Hey, just got finished freshening up the internals on my 74 240d motor. I have the cam timing and crank timing set, and now need to reinstall the injection pump.

From my understanding the procedure goes as follows:

Turn motor to 24* BTDC (cyl 1)
align "marks" on the IP splined shaft and the IP body.
install IP
set exact pump timing using the drip/rotate method.

Here's where I have a question:

The pump "marks" will not stay in position. The pump turns back a few splines as soon as I let go of the splined shaft. I imagine this is due to the spring plate/cam plate/whatever the internal parts are called on the pump wanting to return to the "non-pumping" state. Seems to be the same kinda deal between other brand injection pumps I've installed before, so no real surprise there.

Anyhow, HOW do I keep the mark aligned? Or do I get them as close together as possible before the "return" motion happens and install like that? Or perhaps turn the motor back further to compensate for this?

Any thoughts or info would be much appreciated. Thanks!
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Old 04-30-2010, 11:40 AM
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Join Date: Sep 2007
Location: Long Beach,CA
Posts: 24,405
I pretty much copied exactly what was said in the Manual. I would read the very last pargaraph "note" first as that explains why you are setting the crank at a different degree setting.
The driver is the splined gear on the Fuel Injectin Pump shaft.

From Mercedes Service Manual Engines OM615-617

Set crankshaft to the following values in compression stroke of first cylinder.
615.913 47 Degrees before TDC
615.912 45 degrees before TDC
616 45 Degrees before TDC.

Set injection pump to begin of delivery. For this purpose, keep turning the pump shaft until tooth gap on the driver and the marking on the injection pump are in alignment.
When applying slight pressure on the driver towards the left (opposite to the direction of rotation) the driver will jump back 2 teeth to basic cam circle under the influence of the pressure-loaded camshaft of the camshaft.The 2nd tooth should now be in alignment with the mark on the injection pump housing. Prior to installing the injection pump. Check ounce again whether crankshaft is at 47 degrees before compression TDC of engines 615.913. Or 45 degrees of 615.912 and 616.)

Note: The adjustment of the crankshaft to 47 degrees or 45 degrees before compression TDC is required because the driver has been taken back 2 Teeth.
84 300D, 82 Volvo 244Gl Diesel
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Old 04-30-2010, 12:09 PM
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Join Date: Apr 2010
Posts: 2
Awesome, that is exactly what I was looking for. I must have missed that part in the service manual, I'll have to look it over again and see if its in there and I went temporarily blind.

Thank you very much!
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