Have a euro spec 80's 616 on the stand, never started it, getting ready to. Cleaned the crap off, goodbye PS, AC, filled oil, transferred fuel filter over & primed, feeding it D2 from a jar. Turning it over w/ socket, ports 2-4 of IP put out fuel as it turns over, respond to rack motion, not so for port #1.

Any ideas?

I could transfer IP over from the old engine if need be.

__________________
CC: NSA

All things are burning, know this and be released.

82 Benz 240 D, Kuan Yin
12 Ford Escape 4wd

You're four times

It's hard to

more likely to

concentrate on

have an accident

two things

when you're on

at the same time.

a cell phone.

www.kiva.org It's not like there's anything wrong with feeling good, is there?

Check to see if some one has done something strange to the element on #1 after / during a drip test?

EDIT:- I think it is worth thinking along the lines of a "people" related problem before blaming the machine - especially on a bit that is removed for maintenance purposes.

__________________
1992 W201 190E 1.8 171,000 km - Daily driver
1981 W123 300D ~ 100,000 miles / 160,000 km - project car stripped to the bone
1965 Land Rover Series 2a Station Wagon CIS recovery therapy!
1961 Volvo PV544 Bare metal rat rod-ish thing

I'm here to chat about cars and to help others - I'm not here "to always be right" like an internet warrior



Don't leave that there - I'll take it to bits!

Element piston stuck at top of bore? Delivery valve open with dirt or whatever? How long has it been sitting since the last time the injection pump ran and was the pump dry?

Dry,2-3 years.

__________________
CC: NSA

All things are burning, know this and be released.

82 Benz 240 D, Kuan Yin
12 Ford Escape 4wd

You're four times

It's hard to

more likely to

concentrate on

have an accident

two things

when you're on

at the same time.

a cell phone.

www.kiva.org It's not like there's anything wrong with feeling good, is there?

You might need to turn it over several hundred times before all air is purged from the IP...........not really suited for a socket.

No starter installed yet, I presume (no transmission)...........???

I think it was one of our members who posted this within the last 2 weeks:
Acetone Diesel Mix used to free Plungers in Fuel Injection Pump
I decided to try another experiment which was to see if I could cycle acetone through the fuel system by mixing it with diesel and driving it which would have the benefit of heat and vibration and flushing. Some trial and error suggested that I could run the car on about 1:14 acetone: diesel before the engine started running poorly. After 1 gallon of acetone and 14 gallons of diesel in multiple small batches the car starts and run perfectly on normal fuel.

I have never read of someone using Acetone as the Person above did. I think Marvel Mystery Oil would also work.

A Fuel Injection Pump sitting on the Shelf after being calibrated (meaning the Fuel was clean) can suffer from a sticking Plunger. A Fuel Injection Pump with Diesel Fuel from the Tank can get stuck Plungers due to dried Fuel and Rust.

In the past I have loosened up stuck Plungers by removing the Delivery Valve Holder and Delivery Valve assembly and taking a piece of about 1/8" or slightly thicker Brass Brazing Rod and using as a punch to tap gently on the top of the Plunger. The trick is to do that the Fuel Injection Pump Camshaft is best at the lowest position so that the Plunger has someplace to go.
The MW Pumps do not have a removable Side Cover like the M Pumps do that would allow you to visulize the position of the Tappets.

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84 300D, 82 Volvo 244Gl Diesel

The operational clearance between the piston and bore is very tight. I would try putting some known good penatrating oil in there and let it sit for a day at least before trying to move it.

You should visually notice if it is stuck at the top of the bore by turning the engine over with the delivery valve out. If it is moving examine the delivery valve carefully. If it is staying open no pressure will be developed I believe. Or inadaquate pressure.

A stuck element piston is not that unusual with a pump out of service. You just do not want to chance more damage to the precision fit any more than needed. Hence the soaking with penatrating oil.

When a diesel injection pump is dry and has been sitting around with no storage chemical in it. I do not want it particularily. Preffer a pump off a wreck still full of fuel.

This does not gaurantee anything of course. I just feel the odds of troubles like you are experiencing are less.

I have found that a soaking with laquer thinner seems to cut deposits fairly well. There is something in the back of my mind about acetone.

Acetone is the better or more powerful solvent but laquer thinner is good enough to provide a good soaking cleanout. Probably cheaper but then again I buy it in five gallon cans. I have no ideal if you can run laquer thinner with diesel fuel. Gas cars seem to run on the stuff undiluted fairly well I found out.

Is the delivery valve removed w/ the 32 pt spline tool? Looks expensive to get in the mail when I can swap a known good pump in.

I'll prime it on 50/50 acetone & ATF & soak till I get to it next. May be as simple as an air bind. The stand is a little inclined, #1 port may be a high point.

Swapping pump should be simple as setting both engines to TDC#1 and direct swap?

__________________
CC: NSA

All things are burning, know this and be released.

82 Benz 240 D, Kuan Yin
12 Ford Escape 4wd

You're four times

It's hard to

more likely to

concentrate on

have an accident

two things

when you're on

at the same time.

a cell phone.

www.kiva.org It's not like there's anything wrong with feeling good, is there?

Think it's freeing up. Cut the D2 w/ acetone, primed again- good hard primer, no sponge in the stroke. Get bubbles at the port, & the ATF in the port is diluting.

Could've been the priming, switched my hoses to be sure I was sucking off the bottom of the jar.

I'll drop it on some tires, u bolt it down, fit the adapter, flywheel & starter.

Won't hit the starter till I make sense of my terminals :-)

__________________
CC: NSA

All things are burning, know this and be released.

82 Benz 240 D, Kuan Yin
12 Ford Escape 4wd

You're four times

It's hard to

more likely to

concentrate on

have an accident

two things

when you're on

at the same time.

a cell phone.

www.kiva.org It's not like there's anything wrong with feeling good, is there?

I was repeating what someone said had worked for them; I have never tried it myself.
I will add what you said to my Notes.

__________________
84 300D, 82 Volvo 244Gl Diesel