W115: IP Boss/Spline alignment for reinstall. - PeachParts Mercedes-Benz Forum

bipolardave · #1 01-19-2012, 11:08 AM

Thanks to everyone who posted advice on removing my IP.

It's now back from the rebuild shop and ready to go in.

The FSM process is pretty straightforward. 1. Crank set at 45 BTC on compression stroke. 2. Align marks on IP to be shifted two splines from the mark in the beginning of delivery direction (slightly counterclockwise from mark on housing). 3. Install the IP. 4. Rotate crank to 24 BTC and proceed to fine tune the timing using the drip method.

Ok...I got that.

The thing that perplexes me is how to get the IP aligned properly on the boss.

My W115 has a boss with splines and a key slot. The boss is inserted into the engine where, I assume, it aligns with a key. No issue there.

From the looks of it, although I can have the boss aligned properly there's still "wiggle room" with the IP mounting bolts that might throw me off a spline or two. I can slide the IP into the incorrect grove as there's no corresponding key on it. So I can do everything by the book, but it still won't be indexed correctly.

I understand that I can advance or retard the IP timing to compensate later., but I'd like to get it on the correct spline from the start.

Anyone have any suggestions for insuring correct indexing?

Diesel911 · #2 01-19-2012, 12:52 PM

Unless they returned your Fuel Injection Pump without the Splined Drive Gear attached to the Camshaft of the Fuel Injection Pump there should be nothing visible that has a Woodruff Key.

As far as I can remember the Coupling Tube can be installed in any position. If not install it on the Fuel Injection Pump Splined Drive Gear.

When you stick the Pump into the Engine stick it in in a manner that the Studs/Bolts would be close to center on the Kidney Slots that are on the Flange of the Fuel Injection Pump. That give you room to rotate the Fuel Injection Pump when you drip time.

This timing chart is what I have in my book.
615.913 47 Degrees before TDC
615.912 45 degrees vefore TDC
616 45 degrees before TDC (this is the one with the Pneumatic Governor)

It has to ad ¼ liter of Engine Oil to the Fuel Injection Pump
Set-up the drive Gear (splined) that should already be attached to the Fuel Injection Pump Camshaft to the above timing chart.
Mount new Gasket.
Slip coupling Sleeve on driver and introduce the Injection Pump; tighten Nuts loosely and set begin of Injection.

bipolardave · #3 01-19-2012, 01:15 PM

Quote:

Originally Posted by Diesel911

Unless they returned your Fuel Injection Pump without the Splined Drive Gear attached to the Camshaft of the Fuel Injection Pump there should be nothing visible that has a Woodruff Key.

As far as I can remember the Coupling Tube can be installed in any position. If not install it on the Fuel Injection Pump Splined Drive Gear.

When you stick the Pump into the Engine stick it in in a manner that the Studs/Bolts would be close to center on the Kidney Slots that are on the Flange of the Fuel Injection Pump. That give you room to rotate the Fuel Injection Pump when you drip time.

This timing chart is what I have in my book.
615.913 47 Degrees before TDC
615.912 45 degrees vefore TDC
616 45 degrees before TDC (this is the one with the Pneumatic Governor)

It has to ad ¼ liter of Engine Oil to the Fuel Injection Pump
Set-up the drive Gear (splined) that should already be attached to the Fuel Injection Pump Camshaft to the above timing chart.
Mount new Gasket.
Slip coupling Sleeve on driver and introduce the Injection Pump; tighten Nuts loosely and set begin of Injection.

Thanks!

As always, I'm over thinking this.

I had a new timing chain installed a few hundred miles ago. I'm going to have to account for stretch at some point and wanted the most wiggle room possible.