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  #1  
Old 02-23-2011, 01:46 AM
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IP plungers orientation

Fine people,

In my 1991 W124 300D

I had aleak at two of the delievery valves

While changing the delievery valves O rings and washers...

The crush washers fell inside and I had to use a screw driver to pick them up. I have messed up the original orientation of the plungers and now I can not get the engine to run like before or even idle smoothly.

I tried all the guess work but still could not get it right.

A diesel place wanted to rebuild the whole IP for $2600

The plungers have two holes... one is "small" lowerer than the other "larg"
While the body of the pump has got two holes.

I have done lots of search but could not fine how to set the plungers back to their correct hole orientation.

Would any one able to help with setting the plungers back to the correct orientation please?

Highly appreciated


Regards,

Fitian
<><

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* 1991 W124 300D 480.000 kms Running on WVO
* 1991 W124 300D 230.000 kms Running on Diesel
* 1997 W210 E300 280.000 kms Running on Diesel
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  #2  
Old 02-23-2011, 02:29 AM
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Try this. Post #9

http://www.peachparts.com/shopforum/diesel-discussion/131229-603-delivery-valve-seals.html#post957418
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  #3  
Old 02-23-2011, 10:00 AM
C Sean Watts's Avatar
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Quote:
Originally Posted by MB300D81 View Post
Fine people,

In my 1991 W124 300D

I had aleak at two of the delievery valves

While changing the delievery valves O rings and washers...

The crush washers fell inside and I had to use a screw driver to pick them up. I have messed up the original orientation of the plungers and now I can not get the engine to run like before or even idle smoothly.

I tried all the guess work but still could not get it right.

A diesel place wanted to rebuild the whole IP for $2600

The plungers have two holes... one is "small" lowerer than the other "larg"
While the body of the pump has got two holes.

I have done lots of search but could not fine how to set the plungers back to their correct hole orientation.

Would any one able to help with setting the plungers back to the correct orientation please?

Highly appreciated


Regards,

Fitian
<><
Most likely, you do not need a rebuild. Besides, that is a bit pricey. PM me if you do need a new pump, I have them new from Germany, with warranty, for about half that.

You DO need to have it calibrated (not a DIY job) as moving internal parts and not getting them back to the exact same positions will easily cause what you're describing.
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  #4  
Old 02-23-2011, 01:44 PM
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I don't know what prices are running, but my local shop gave me a price of $450 to do DV seals, re-seal the outside of the pump, turn up the full-load and high-idle, and calibrate the pump. As Sean says, $2600 seems high for only part of this service.
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  #5  
Old 02-23-2011, 02:12 PM
Diesel911's Avatar
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Location: Long Beach,CA
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Quote:
Originally Posted by MB300D81 View Post
Fine people,

In my 1991 W124 300D

I had aleak at two of the delievery valves

While changing the delievery valves O rings and washers...

The crush washers fell inside and I had to use a screw driver to pick them up. I have messed up the original orientation of the plungers and now I can not get the engine to run like before or even idle smoothly.

I tried all the guess work but still could not get it right.

A diesel place wanted to rebuild the whole IP for $2600

The plungers have two holes... one is "small" lowerer than the other "larg"
While the body of the pump has got two holes.

I have done lots of search but could not fine how to set the plungers back to their correct hole orientation.

Would any one able to help with setting the plungers back to the correct orientation please?

Highly appreciated


Regards,

Fitian
<><
I am not sure which parts you are speaking off.

#23 is the Delivery Valve Holder (sometimes called a Pipe in the FSM)

#27 The Delivery Valve Spring

#44 Is the Delivery Valve. It has 2 pieces and the 2 pieces are mated to each other meaning that parts should not be mixed. The Central Valve in the Delivery Valve is only fitted to one side. This means that the Outer Ring portion of the Delivery Valve is only supposed to fit one way.

#47 is the Plunger and Barrel Assembly (called an Element in the FSM). The part on the bottom (in the center) that goes up and down is the Plunger.

The outer tube is the Barrel. The Barrel has a slot (in the upper middle) in it that lines up with a Pin in the Fuel Injection Pump Housing. If for some reason the Barrel us pulled up and rotated the Pin is not going to fit into the slot.
If it is torqued back in place like that there is a chance of damaging the Fuel Injection Pump Housing. It is even possible to bend the Pin inside of the Fuel Injection Pump Housing.

One of the ways to tell if the above has happened is when installed the Delivery Valve Holder will stick up higher than the properly installed ones.

#48 connects the Plunger to the Rack. If the Plunger is Pulled out completely and you cannot remember how it was lined up; you will have to use trial and error because the Plunger can go in 2 ways.
Attached Thumbnails
IP plungers orientation-z-pump-element.jpg  
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  #6  
Old 02-23-2011, 02:45 PM
whunter's Avatar
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Answer

Quote:
Originally Posted by MB300D81 View Post
Fine people,

In my 1991 W124 300D

I had aleak at two of the delievery valves

While changing the delievery valves O rings and washers...

The crush washers fell inside and I had to use a screw driver to pick them up. I have messed up the original orientation of the plungers and now I can not get the engine to run like before or even idle smoothly.

I tried all the guess work but still could not get it right.

A diesel place wanted to rebuild the whole IP for $2600

The plungers have two holes... one is "small" lowerer than the other "larg"
While the body of the pump has got two holes.

I have done lots of search but could not fine how to set the plungers back to their correct hole orientation.

Would any one able to help with setting the plungers back to the correct orientation please?

Highly appreciated


Regards,

Fitian
<><
All you need is calibration roughly $1000.
The price they gave is IMO very high.


http://www.youtube.com/watch?v=POlOSBVIXe8

http://www.youtube.com/watch?v=Qty6ZK8o6U8

http://carlton.carmechanic.net.au/diesel-engine-tuning/1962

http://www.moorediesel.com/diesel_fuel_injection.html

http://www.sydneydieselcentre.com.au/service.html

http://www.autosource.com.au/diesel-cars.php

http://www.dieselject.com.au/

http://www.griffithdiesel.com.au/

http://lismorediesel.com.au/

http://www.hastingscbd.com.au/dieselinjection.html

Deutz Australia Pty Ltd
Engines-Diesel &/or Equipment & Parts - Springwood, QLD
Dennis Court Unit 12/ 8 Dennis Rd, Springwood QLD 4127, Australia
(07) 3290 0988

Diesel Technology (Springwood) Pty Ltd
Engines-Diesel &/or Equipment & Parts - Springwood, QLD
17 Westerway St, Springwood QLD 4127, Australia
(07) 3208 7124




.
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  #7  
Old 02-23-2011, 03:00 PM
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Quote:
Originally Posted by MB300D81 View Post
A diesel place wanted to rebuild the whole IP for $2600
That means they really don't want to rebuild your IP.
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  #8  
Old 02-23-2011, 03:19 PM
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Note: MB300D81 Location: Australia

It dose not matter what the price in the US is.
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  #9  
Old 02-23-2011, 05:10 PM
92 300D 2.5L OBK #59
 
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Look at this link. http://www.peachparts.com/Wikka/OM606DeliveryValveSeals it's pretty much the same as this: http://www.peachparts.com/Wikka/OM602InjPumpFuelLeak

If you put it with the numbers up. It's correct. Air in the system/lines takes a bit to work out.

I might be totally wrong. But K.I.S.S. applies here. Unless the pump was wonkered up to begin with.
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  #10  
Old 02-23-2011, 08:25 PM
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Hmmm

Quote:
Originally Posted by Diesel911 View Post
Note: MB300D81 Location: Australia

It dose not matter what the price in the US is.
I Disagree.

Customers can ship them here for calibration or rebuild.
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  #11  
Old 02-23-2011, 08:39 PM
Diesel911's Avatar
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Quote:
Originally Posted by whunter View Post
I Disagree.

Customers can ship them here for calibration or rebuild.
And, if there is a Warranty issue who will pay the shipping to the rebuilder and back?
On the intitial rebuild would there be a duty on it?
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  #12  
Old 02-23-2011, 09:54 PM
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heh not sure what shipping to AU would be, but I've got a parts car 93 turbo 2.5 if that is the same motor in yours... I could ship it to CSEAN and have him do a set of DV seals and gaskets for you, and get it shipped up easier than dealing with a recal...
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  #13  
Old 02-24-2011, 01:06 AM
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Thanks to all of you for your fast and kind replies.

I tries with numbers up ... did not get rid of the misfiring and still idle rough.

The wholes on either side of the plungers were set both ways and yet still getting the same result.

At one stage, I placed the plungers with the larg holes all lined up facing towards the front of the car and the engine started right up however the rpms went to the roof. and the shut off arm could not stop the engine. I had to pull the fuel hose and let it use all the fuel to stop "bad experience"

I finally rang a diesel place and booked it in for resetting/calibration etc.

cost is unknown but it starts from $2600



I will report back when it is done.

Regards
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* 1991 W124 300D 480.000 kms Running on WVO
* 1991 W124 300D 230.000 kms Running on Diesel
* 1997 W210 E300 280.000 kms Running on Diesel
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  #14  
Old 03-22-2011, 05:47 AM
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Fine people,

I just got the car back from the diesel center.

The car is drives well however, I noticed...

it is reving somehow higher than before. Accelerator cable is not tight.
RPMs is sitting between 5000 and 10000 RPMs while idle...

What is the correct idle rpms?

The knock is louder and sharper than before and does not go away.
The car is running on pure diesel.

I took the car back to the diesel center and they reckon the idle can be lowered down but I am not sure what is the correct rpms.

Can someone advise on that please?

Regards
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* 1991 W124 300D 480.000 kms Running on WVO
* 1991 W124 300D 230.000 kms Running on Diesel
* 1997 W210 E300 280.000 kms Running on Diesel
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  #15  
Old 03-22-2011, 10:06 AM
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Quote:
Originally Posted by Diesel911 View Post
Note: MB300D81 Location: Australia

It dose not matter what the price in the US is.
1 Australian dollar = 1.0122 US dollars

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