So I'm attempting to change the primer pump on my not-yet-on-the-road-wife upsetter (240D), and for the life of me I can't seem to get it to come out. Are there any tricks? I don't care if I destroy the old pump, it's bad. I've already removed the lines from the lift pump to provide access to the hex on the primer, but I just can't seem to get anything to it. I'm down to a few major stumbling blocks to getting this thing on the road, and this is one of them. (I also have to adjust the throttle linkage, replace the rear brake line and mount an expansion tank for the 300cd radiator I put in it.)

Are you using a crow's foot wrench?

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1977 300d 70k--sold 08
1985 300TD 185k+
1984 307d 126k--sold 8/03
1985 409d 65k--sold 06
1984 300SD 315k--daughter's car
1979 300SD 122k--sold 2/11
1999 Fuso FG Expedition Camper
1993 GMC Sierra 6.5 TD 4x4
1982 Bluebird Wanderlodge CAT 3208--Sold 2/13

Unfortunately all my crow's feet are line style (not fully open). Anybody know what size it is so I don't have to buy a full set of 22mm+ crow's feet? I think it's 24mm, but I'm not sure.

you could remove the whole lift pump assembly to have full access to the primer pump.

I cut the box end off an old 17mm wrench. With the open end at 5", it worked fine. This was on an 83 240d. Make sure to get the old sealing ring out.

This is the old style, it's definitely larger than 17mm, I think I may try cutting a 24mm wrench...

See if you can get a pipe wrench or maybe vice grips on the body of the old pump.

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1981 300TD 310k miles
1970 280sel 172k miles
1966 230 Fintail 162k miles

"Where are we going? And why am I in this hand basket?"

Vise Grips from above. Crush and pinch. Then unscrew.

If you are someone else has some plumbing tools; see if there is a Basin Wrench.
It will squash the Hand Primer but the advantage is that it grabs down at the bottom of the Hand Primer.
See pics.

Attached Thumbnails

   

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84 300D, 82 Volvo 244Gl Diesel

I think I'll give that basin wrench a try, it's cheap enough. Thank you

This. My IP is out for a rebuild, but I believe it's either a 19 or 21mm.

I had the exact same problem as the OP. Since I had to wait for the pump to arrive, I went ahead and picked up a set off eBay for under $20.

I couldn't drive the car for a week, but I saved lots of pain and frustration.

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1974 240D "Boldie" 170K.- New timing chain/freshly rebuilt IP/replaced valve seals/injectors/upgraded stereo/new Bilsteins with Yokohamas/fresh paint and rocker panels plus lots of welds.

Basin wrench wins. The flats are closer to 24mm, and I didnt have a crowsfoot big enough. The pump came right out with the basin wrench

Just measured it, it is indeed 24mm...

My bad. Maybe I'm thinking of the newer Bosch replacement pump that I put back in.

My set of el cheapo crow's feet came with a 24mm. Probably the only time it will ever be used was to remove that busted plastic hand pump.

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1974 240D "Boldie" 170K.- New timing chain/freshly rebuilt IP/replaced valve seals/injectors/upgraded stereo/new Bilsteins with Yokohamas/fresh paint and rocker panels plus lots of welds.

yeah, the new one was 17mm, if I could have located a 24mm straight crows foot locally cheap, I'd have gone that way. The sets I found locally ended at 21mm or less. As is, the basin wrench was 4.99 at harbor freight, and I don't even care that I went to harbor freight since I'll probably only only use it a handful of times... I'll actually probably lose it before the next time I need it.