My 190d developed a drip every two seconds. It leaks between the back case and main body of the injection pump. I need instructions on the removal and replacement of the injection pump. Please help!
Karl

How about a picture where the leak is? Is it on top? Or coming from one of the removeable plates? Funny, My name is Karl and I have a 84 190D also.

If you are talking about the back plate, cant you replace the seal with the pump on?

Hi Karl,

It is leaking where the back case cover meets the main body. Both are cast parts and not a steel cover plate. I am not aware that this pump was ever remaned for the newer fuels and figured that it is time to put the synthetic parts into it.
Karl Alan

Karl,

I believe that most stuff you are going to do to the IP can be done with it in place and most responders to you inquiry will try to help you confirm that it really does need to be removed to do what you need to do. I fully support those efforts.

I just replaced a worn out IP on my '84 2.2, so if you need to R & R....

Assuming you have already removed everything needed to get access to the pump, and all the fuel lines to and from the pump:

Set the engine timing to TDC.
Remove the vacuum pump.
Remove the 3 long bolts that hold the IP body in place. The nut on the bottom bolt is a bugger to get a hold of coming off and going on.
Remove the bolt on the end of the IP shaft. It turns clockwise to remove.
I think I used a magic marker to mark the shaft location in the gear. I'm not sure that's all that important.
Remove the IP by moving it rearward out of the drive gear.

Do what you gotta do.

To set the timing on the IP if you have moved it:
Removed the plug on the driver's side of the IP's body.
Line up the line on the pump cam with the lines in the center of the "window" you unplugged.
Install the IP shaft into the drive gear. Check if the timing marks are still lined up. (Also confirm that the engine timing is still at TDC). If not close enough to be able to adjust with the adjusting bolt on the mount, try again. I think it took me 3 tries to figure out where it had to be going in to end up where I wanted it when it was in.

I am sure that if I forgot anything important, someone will let you know.

__________________
Greg
2012 S350 BlueTEC 4Matic
2007 ML 320 CDI
2007 Leisure Travel Serenity
2006 Sprinter 432k
2005 E320 CDI
1998 SLK230 (teal)
1998 SLK230 (silver)
1996 E300D 99k, 30k on WVO
Previous:
1983 240D, on WVO
1982 300D, on WVO
1983 300CD, on WVO
1986 300SDL 237k, 25k on WVO (Deerslayer)
1991 350SDL 249k, 56k on WVO - Retired to a car spa in Phoenix
1983 380 SEC w/603 diesel, 8k on WVO
1996 E300D 351k, 177k on WVO