I understand that you can put 6.mm 606 IP plungers into a 603 IP pump, correct me if I am wrong. Reason converting from a electonic IP pump to a mechanical pump. Can a experienced mechanic do the parts swap and have a Bosch shop set up the pump after?

I don't know if it has to be a Bosch shop but it has to be a shop that can calibrate the pump after swapping plungers. Most automotive repair shops have neither the equipment nor the talent to do this work. In most cases, they don't even have the right accent

Dieselmeken shows difference between 5,5 mm & 6,0 mm in same pump - YouTube

[edit] My point is, have a pump shop do all the work.

Sixto
87 300D

Beyond not having the correct equipment, calibration spec or skill:
Compared to gasoline Engine Mechanics very few Mechanics are Diesel Mechanic. Compared to Diesel Mechanics there is even fewer people who have training to fix Fuel Injection Pumps.

It is not just a matter of swapping the parts. You need to follow proper procedures and keep everything extremely clean. Most Mechanics are not able to do that.

More than several times a year some of our forum Member try changing the O-rings on their Fuel Injection Pumps only to end up in trouble.
Replacing the Plungers and Barrels (Elements) is more complicated that changing the O-rings.

I also think that in general most of the Mechanics out there are "parts replacers" not not rebuilders.

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84 300D, 82 Volvo 244Gl Diesel

Based on my experience with diesel shops, I get the impression that they would rather swap the parts in AND do the calibration. Not so much because they make more money, but because they know that the elements are installed correctly and that they're not chasing problems created by improperly installed parts.

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-Evan


Benz Fleet:
1968 UNIMOG 404.114
1998 E300
2008 E63


Non-Benz Fleet:
1992 Aerostar
1993 MR2
2000 F250

My experience when calibrating Fuel Injection Pumps is that a tiny little movement in the Fuel Adjustment for each Element can cause a big change in the Fuel Delivery. So I do not see how just swapping out the Elements would be even close.

The other issue is that the Begin Injection of each Element is set (by changing Spacers at the top of the Roller Tappets) and timed to the IP Camshaft with a Degree Wheel on the end of the IP. I do not see how that could come out right just by swapping out the parts.

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84 300D, 82 Volvo 244Gl Diesel

I guess the question I was asking is if I could dissasemble the 606 pump and remove the plungers myself and take them and the 603 pump to a IP shop to be installed. I have built Diesel engines for 10 years and have built Street Rods for over 30 years. Think I could handle this? As for the accent I could probably fake that!!!

Go for it! And, report back on your results.

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84 300D, 82 Volvo 244Gl Diesel