This question might or might not be a problem for me, but here goes: how does one get the relationship between injection pump state and engine state approximately correct, so that when you go to do the final injection pump timing via the drip method the correct rotational position is within the range of adjustment of pump angle? Does an injection pump rebuilder typically deliver you a pump with the shaft set at some defined angle, and then you rotate your engine to the corresponding point (say, cylinder 1 TDC compression) before installing?

This might not be an issue for me... I have two pumps in play. I dropped a low miles Pick'n'Pull pump off at the rebuilder for an opinion; so far I have not heard back from them. Depending on project timing I might end up just transferring the injection pump from my old engine straight over. In that case I think that I can just set the old engine angle to TDC before removing, then transfer over to the new engine (which came at cylinder 1 TDC compression). But it got me wondering about the general case. Is it just trial and error via the drip method: try and time it, find out you can't get it, pull the IP, rotate the cuff, install again, rinse, repeat?

Thanks for your education on this...

Kurt

__________________
- '79 240D - engine swap complete! Engine broken in! 28-31 mpg! Lovin' the ride!
- '86 190D (W201-126) - 2.5 NA engine, 5 speed, cloth interior, manual climate controls, 33-34 mpg (sold to forum member).

NO, the rebuilder does NOT normally set it on TDC for shipping.

You must rotate and insert the MB special injection pump TDC locking tool, before installing the pump.

INJECTION PUMP LOCK PIN - EARLY MODEL
MB# 900 589 86 73 00

900-8673... DIESEL INJECTION PUMP LOCK PIN - EARLY MODEL...Locks diesel pump cam to maintain timing during pump installation...OM615, 616, 617, 621



Diesel Injection:
Diesel Injection:



.

__________________
ASE Master Mechanic
asemastermechanic@juno.com

Prototype R&D/testing:
Thermal & Aerodynamic System Engineering (TASE) Senior vehicle instrumentation technician.
Noise Vibration and Harshness (NVH).
Dynamometer.
Heat exchanger durability.
HV-A/C Climate Control.
Vehicle build.
Fleet Durability
Technical Quality Auditor.
Automotive Technical Writer

1985 300SD
1983 300D
1984 190D
2003 Volvo V70
2002 Honda Civic

https://www.boldegoist.com/

Can anyone help me locate a workshop manual for a om 616 engine, Thank you

If you need a paper version, there are a half dozen listed on Ebay at this very moment.

__________________
When cryptography is outlawed, bayl bhgynjf jvyy unir cevinpl.

And MB USA has it online:

http://www.startekinfo.com

there "MB Workshop Resources" > "Service Manual Library CD/DVD". Choose model 123.

When you go to the Ad it has: "TOOL HAS BEEN DISCONTINUED"

__________________
84 300D, 82 Volvo 244Gl Diesel

Hello , i own a w115 and i installed a w123 240D engine. Since the engine has been standing a while i decided to install a new set of big end bearings and check the rest out a bit. When it came to starting it up i had a huge problem tough, since i had removed the Injector pump so the engine would fit in the engine bay. I am not a qualified mechanic yet , but my old man is and has been working on these cars since they were produced. To install the injector pump and getting it to work turns out to be easy . Turn the engine to 42 degrees BTDC , fit the injector pump with mark lined up and it will start. I will explain , the mark on the ip sets it so it still has to inject on cyl nr1. So it still has a way to go before it makes enough pressure to inject. Trust me it works , i just started my engine up and it sounds great. This IS a sure fire easy way to get it working without any fancy drip or flow tests. Fine tuning can be done later.

The generic instructions in the Manual if you Fuel Injection Pump is correctly marked are to turn the Engine in the drecton of rotation until on the Compression stroke of Cylinder #1 (you can tell by looking at the first Cylind Camshaft Lobe Position) at 24 degrees on the Crankshaft before top dead Center (OT on the Crank).

If your Fuel Injection Pump is marked correctily the little line on the Camshaft Bearing Cap is lined up with the Screw in the Picture.
You would line missing splines on the Drive End of the Fuel Injection Pump with that mark on the Camshaft Bearing Cap as showning the Picture. The stick the Fuel Injection Pump into the Engine with the mounting Studs in the Middle of the Slots on the Pump Flange and install it.

Note that the Fuel Injection Pump that has the timing marks correct has the mark on the Camshaft Bearing Cap lining up with the Screw on the Bearing Cap as in the Pictue.

Attached Thumbnails

 

__________________
84 300D, 82 Volvo 244Gl Diesel

I think you got the Number transposed and it is 24 degrees.

__________________
84 300D, 82 Volvo 244Gl Diesel

Following the procedures in the FSM has always worked for me. The procedure above offers a 50% probability that the #1 piston won't even be on the correct stroke. Trust me, you will be on the wrong stroke half the time.

Good luck with that if the initial crankshaft angle is 42 degrees BTDC.

__________________
When cryptography is outlawed, bayl bhgynjf jvyy unir cevinpl.

I have not gone out an looked at the Crank Balancer but I am guessing that there is no 42 degrees BTDC marks at all there.

__________________
84 300D, 82 Volvo 244Gl Diesel