So I have decided the IP is the culprit....I have an extra one off my parts car that I plan on installing.

This will be my first experience doing an IP R&R...are there any special tools I will need to do this?

Words of wisdom and/or links to a DIY write-up on this would be great!

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1981 240D

Whoa, before you go a swapping the IP try running a couple cans of Diesel Purge straight through the fuel system. You probably have some gunk built up in the pump. Diesel purge will clean it out. You may not need another pump. A diesel purge is much easier than swapping IPs. It's worth a shot.

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Getting the IP off is not an easy job on a 617. Ive done it a few times on my 616s and that was a bear each time. 617s are harder because of less room. Good luck saving another WVO daydream/nightmare.

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1985 Euro 240D 5 spd 140K
1979 240D 5 spd, 40K on engine rebuild
1994 Dodge/Cummins, 5 spd, 121K
1964 Allice Chalmers D15 tractor
2014 Kubota L3800 tractor
1964 VW bug

"Lifes too short to drive a boring car"

Diesel Injection:
Diesel Injection:






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1983 300D
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You have done a compression check on this engine I hope?