OM603 Won't Start after IP Swap
 

I just put my OM603 back together after swapping pumps. It had a horrible misfire at idle and shook really bad, so after some reading here I decided to put in my spare, untested injection pump. However I was told the donor car drove to the junkyard. It was dented, rusty, moldy, and just plain a nasty car beyond repair, the motor however did look pretty clean, and like I said the guy told me it drove itself to its final resting place. I can't verify that. I resealed the oil seals with dealer gaskets and installed viton DV seals and new crush washers. The pump is timed correctly, however I did intentionally reinstall it at 14* ATDC.

Cranking the car it cranks really strong, but never even starts to cough to life.

We pulled the 6 hard lines off of the injectors and no fuel is coming out of them.

I pulled the line from the lift pump to the canister fuel filter off, sprayed fuel, so the lift pump is good.

Pulled the line off the canister filter to the IP, sprayed fuel. So fuel is leaving the filter and going to the pump.

But no fuel will leave the pump.

What to test now? All the lines look hooked up correctly.

The only thing I did notice is the stop lever on the "new" pump doesn't sit as high as the stop lever on the old pump and the action of it does not feel as tight, however it does feel like it is moving something when you push it down.

Do you know how long it was stored and in what conditions?

When you did the DV seals did you see any corrosion on the valves?


Try cranking a bit with the pedal fully depressed and the lines loosened at the injectors. The pump is bone dry by now, it could take a bit. Faith. (I hope)

Try these steps, and pump while a friend cranks it.

1) I filled in the main fuel canaster with diesel to the top
2) I syphoned the fuel line going to this canaster
3) I retightened this canster and then focused on the small clear filter
4) I syphoned the fuel line going to the small clear filter and attached it very tightly
5) I quickly manual primed the Injector Pump until I saw fuel coming into the clear filter
DO THIS ONE FOR SURE ----> 6) I untightened the injector pump bleed screw and primed until I saw fuel and tigtened it back up
7) I started the car and it ran like crap, while it was running I hand primed the injector pump a few more times and it ran like NEW.

I wasnt aware the 603 had a manual primer or a bleed screw. Where are they on the pump?

See if you can get the car to run with wd 40 through the air filter chamber. This may ease clearing the injection pump and lines of air faster.

I will try that, thanks.

I left the trunk open last night my trickle charger didn't charge the battery overnight. I charged it for like a half hour and cranked on it. I got fuel to start coming out of the back 2 lines. So maybe a bit more cranking is in order. I've got errands to run until like 9 but I left the car on the actual charger so it should have plenty of juice when I get home.

Bleeding these darn things always takes forever. Took me two hours one time, while giving the starter lots of breaks (I'd do something else for 5-10 mins).

It doesn't.

Got it started, runs WAY better than it ever did, it isn't shaking itself apart anymore awesome!

However it won't turn itself off, I found the vacuum leak, but I can't recall where it used to go. Any help?

It comes out the green thing and runs across the motor.
http://i149.photobucket.com/albums/s...o/2073bd73.jpg
http://i149.photobucket.com/albums/s...o/36e0878d.jpg
http://i149.photobucket.com/albums/s...o/5a33836b.jpg

Across? If it's that long it might be the transmission line. There are no lines going across.

That does look like the black line to the transmission modulator.

That would explain its length, thanks Jeff!