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Old 04-07-2012, 07:50 AM
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Join Date: Mar 2003
Posts: 379
You could allign the marks on the IP shaft,set the crank on 24 degreed BTDC on the compression stroke and install, OR set the IP shaft on the second tooth before the wider (missing)one on the IP splined gear with crank at 45 degrees BTDC.

The reason for this :Because the cam lobe is pressing against the 1-st pump element roller follower,it`s easy to lose the adjustment while trying to reinstall the pump-and the shaft could slide back a little.So you`ll end up with a retarded injection.
So the IP gear,the splined sleeve and the intermediate shaft have 68 splines/teeth. 1 tooth/spline correction=5,3 degreesX2=10.6 degrees correction counted on the crankshaft.One moves back the IP cam 2 splines(roughly 21 degrees on the crankshaft),so that the second tooth on the IP gear points agains the IP mark and installs the pump with the crank set at 45(24+21 correction)degrees BTDC on the compression stroke.Then the drip method...

The same applies to other engines too-for example on om621's or om615 2.0litre the IP is installed at 26 degrees BTDC. The manual suggests setting back the IP shaft two splines and installing the IP at 47 degrees BTDC(that is 26+21degrees) -compression stroke-on crankshaft.
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Old 04-08-2012, 05:52 PM
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Join Date: Feb 2012
Posts: 21
Very interesting. I set the crank at 24* and lined the splines on the injection pump up then slid it in. It's a hard starter when it's really cold out, but once it's warm it fires right up. Great power but it does blow some coal. I haven't fine tuned the pump timing yet though.

The slight miss at idle is still there. I haven't been able to figure it out or actually really take a lot of time to do it.

Overall it runs and drives really good. It's got more power than most other 300Ds I've driven around here.

The glow plugs work if you **** with the key enough to get the relay to function.
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