The Tubo Fuel Pump does not use the Disc Valves. One comes in from the Bottom and the other is under the oulet Fitting.

The Hand Primer is located in the front middle.

The Valve kit for the Turbo Models of 617s in the picture comes with out the tiny O-ring and does not have the Copper crush Washer for the 30mm Plug.

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84 300D, 82 Volvo 244Gl Diesel

The tiny o-ring is for the non turbo model i believe. The turbo's have a roller bearing.
I purchased a turbo fuel/lift pump kit from Phil and also did not receive the large crush washer for the 30mm plug....must be a single item part.

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1985 300D, 250k
1980 300SD, 180K

Thanks for posting this



The "turbo" lift pump parts do look different.

Do you happen to know if the lift pumps fitted to the non turbo MW IPs were the same as the turbo versions? Or is it more complicated than just a difference between M / RSF and MW pumps?

Here's a picture of a "MW" lift pump I've got





This is a MW IP that was fitted to an early OM617 / 300D

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1992 W201 190E 1.8 171,000 km - Daily driver
1981 W123 300D ~ 100,000 miles / 160,000 km - project car stripped to the bone
1965 Land Rover Series 2a Station Wagon CIS recovery therapy!
1961 Volvo PV544 Bare metal rat rod-ish thing

I'm here to chat about cars and to help others - I'm not here "to always be right" like an internet warrior



Don't leave that there - I'll take it to bits!

Stretch - What are the 2 types of IP pumps you have posted - year of car and pump type?

First IP picture has that rectangular brass colored access port (?) and what i will call the newer fuel/lift pump with 3 holes on top, while the second IP picture has the lift pump with fuel inlet port on right side of fuel/lift pump.

Are the roller bearings associated with non turbos or type of pump?

Thanks

Chris

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1985 300D, 250k
1980 300SD, 180K

See the Pic showing the O-ring (at the base of the red arrow) that goes in an internal groove in the Pin Bore. The One without the Roller also has an O-ring in there.

The one you got from Phil is the one I have pictured and Mercedes sells it as a Valve Kit. And, that kit comes without the 30mm Plug Gasket and no O-ring.

When I did Mine I got the Right sized O-ring from a Local BMW Dealer and I simply put a gasket sealer on the threads at the base of the Plug and left the Copper Crush Washer Alone.

Mercedes sels the 30mm Plug Crush Washer as a seperate part.

One of our Members in another thread came up with the Mercedes O-ring part and He said they are now Viton.


If you want the complete Kit in one of the Threads one of our Members bought that kit from a Bosch Fuel Injection Shop.

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84 300D, 82 Volvo 244Gl Diesel

The partly taken apart one is from My Turboed 300d and off of an MW Pump.

The M pumps have the 2 holed Flange and look like the one this thread was about.

After that my experience is too limited. I only have My own Vehicle and what I read on the various forums.

When I worked in the Fuel Injection Shop about 1975-1980 all of the Bosch Lift Pumps I can remember had the Roller Tappet in them. But, the Pumps I saw were mosly for truck applications or the Older Mercedes Cars and Thermokings with Mercedes Engines.
The Mercedes Diesel Cars made in 1975-1980 that had any Fuel Injection or Lift Pump issues would have been taken care of under the Mercedes Warranty. Meaning that I would never have seen those Pumps in the Shop Where I worked.

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84 300D, 82 Volvo 244Gl Diesel

Didn't know the roller bearing section was serviceable or about the o-ring location.

Just finished tearing down my extra pump...thanks for showing the exploded view of the roller section. Now to chase down 2 more parts.


I didn't find ANY of the 3 o-rings shown above during my tear down. I did locate the small o-ring, 003 997 82 45, in my rebuild kit. Do i need the other 2 o-rings Stretch shows or just the crush washers?

Does the small o-ring just sit on the shaft during reassembly?
How do i extract the piston, toward the roller bearing or towards the 30mm plug? After looking at the cylinder section with better light i see a stepped section on the roller side preventing travel so towards the plug, right?


chris

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1985 300D, 250k
1980 300SD, 180K

The little O-ring is the only O-ring on the Turbo MW type Lift Pump that uses the Kit I posted the pic of with the hard Plastic T Valve in it (turbo MW Fuel Injection Pump).

Ask Stretch to be sure but I am guessing the 2 larger O-rings are used on the Lift Pump that has the Disc Valves like the one this thread is about (Valves similar to the Valves in the Vacuum Pump).

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84 300D, 82 Volvo 244Gl Diesel

Got it.

Looks like my pump has a frozen piston. Will not budge in any direction.

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1985 300D, 250k
1980 300SD, 180K

Spray Penetrating Oil down into the little hole the Push Rod goes into and let it sit and soak in.
With the 30mm Plug Removed and the spring out; insert the Push Rod and turn the Pump upside down and use an Aluminum or Brass Punch against the Rod and gently tap the Piston down. That will push the Piston out until it is flush with the Plug area.
After that you need to find a skinny Punch to continue tapping out the Piston with the Pump Housing supported so there is room for the Piston to come out.


.

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84 300D, 82 Volvo 244Gl Diesel

Sprayed some Kroil yesterday and then used a 14mm deep socket, mounted pump in bench vise and applied a little pressure ....no go. Sprayed more and quit for the night. Will have another go with a punch today.

A do have another IP with lift pump attached if this one ends up with damaged cylinder walls.

Chris

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1985 300D, 250k
1980 300SD, 180K

FYI... Thanks for the picture of the rebuild kit as my local dealer was having trouble sourcing one for me!!! I wish I had found this thread a week ago, it would have saved me a lot of trouble. I did end up finding a Bosch gasket kit that seems to be for all the FP/K feed pumps. It has all the parts shown in the rebuild kit and more. including the 30mm washers.

If you still have it how about posting the Bosch Kit part number and how much the kit cost.

Also there is other threads that have the same info posted in this thread on the Valve Kit.

DIY Repair Links
http://www.peachparts.com/shopforum/diy-links-parts-category/

http://www.peachparts.com/Wikka/DoItYourSelf


.

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84 300D, 82 Volvo 244Gl Diesel

Bosch gasket kit for all the FP/K feed pumps: DGK301 $14.60 CDN (stock item)
Bosch gasket kit for the PES 5 MW 55/320 RS 4 (NA-non turbo, 1975 300D W115) IP's: DGK128 $37.25 CDN (special order from the US)

I am picking up the IP kit today so hopefully tonight I will post pictures of both kits.

I can also confirm today that MB Canada has told me that the lift pump and valve repair kit are NLA in Canada. I am still waiting on a response for the IP gasket kit but I am pretty sure it will also be NLA as they have told me in the past that the IP itself is NLA.

I don't know where you would get them but when I worked in a Fuel Injection Shop there was 2 aftermarket companies that made gasket kits and even hard parts for a variety of Fuel Injection Pumps including Bosch.
SPACO is one of them. (I think US Diesel in Texas sells them but not sure.)
In one of Our Threads I believe I saw a Kit made by FLAG.

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84 300D, 82 Volvo 244Gl Diesel