616 Lift Pump rebuild questions...
 

So I finally got around to ordering the lift pump rebuild kit and I am ready to pull it off and put it on the bench....just wondering if there is anything I should know before I tear into it...I have read that there are some o-rings that don't come with the kit that should be replaced?....does anyone have part numbers for these or know where I can get them?

There may be better sources but I bought the little O-ring from a BMW Motor Cycle Dealer and had to wait over 1 week for it. The siz info is in one of the below threads.

However, any Bosch Fuel Injection shop should be able to get the complete kit. Cost???
Unless they are too mangled Copper Washers can be reused by heating them Red hot and letting them cool. If you decied remove the Large 30mm Plug on the Lift Pump do not try to pry the skinny Copper washer out as you will ruin it (unless you have a replacement). Just leave it there and apply some thread Sealant around the threads near the Hex of the Plug when you assemble it.
Lift Pump, Fuel Supply Pump rebuild kit
http://www.peachparts.com/shopforum/diesel-discussion/260325-anybody-know-good-fuel-pump-replacement-diy-page-post2284880.html#post2284880
Lift Pump, Fuel Supply Pump about sanding the Valves has the small O-ring size
http://www.peachparts.com/shopforum/diesel-discussion/266857-lift-pump-rebuild.html?highlight=lift+pump+kit

You might want to take a peek inside and look at one of the Valves. The Fastlane kit has Plastic Poppet type valves in it. One of our members took apart a Euro 616 lift pump and it had Disc type Valves in it.

Where does this o-ring go that is not included w/ the kit from Fastlane...is it necessary to replace it?

That info is in the thread:
http://www.peachparts.com/shopforum/diesel-discussion/266857-lift-pump-rebuild.html?highlight=lift+pump+kit

In the last pic in post #9 you can see the O-ring.

If you enlarge the pic in post #11 you will see an skinny yellow Arrow pointing to where the O-ring goes.

You will need to decided if you want to replace the O-ring.

Most common symptom of a bad O-ring is Diesel Fuel gets into your Engine Oil. You Oil level on the Dip Stick rises.

Less common symptom is that some of the Motor Oil that lubes your Fuel Injection Pump gets sucked into the Fuel Supply Pump and mixes with the Fuel and is burned in your Engine.
It shows up as a loss of Motor Oil on the Dip Stick where there is no obvious Oil leaks and you Exhaust smoke can smell bad.
Your Fuel could have a gray tinge to it from the soot in the Motor Oil.

This may be of use to you

http://www.peachparts.com/shopforum/diesel-discussion/294499-refreshing-fuel-pump-om617-european-spec-%96-non-turbo.html

Thanks for the link...I had been looking for a write up like this but hadn't came across anything.

You're welcome - is it the same pump as the one on your 240D?

I haven't checked to see if it is the same, but it gives me the general idea that I was looking for.