Hi to everyone out there in Mercedes land. I hope this question finds a good home with some w115/ 300d owners out there.

We have a 76' 300d. It has licked its share of peanut butter....... I was told the car itself has over 700K on her. From the condition of everything, I believe it!

We put about 12,000 miles on it with no problems(besides the rust in the tank clogging filters).

This past December it started to have a little trouble starting. Kinda like it was starving for fuel...Finally it reached an impasse. On Christmas eve she said NO.

Fast forward to June the 1st. After testing, proving disproving, adjusting -etc. It seems that there is a Fuel delivery problem in the pump, or the side lift pump. When cranking a ticking can be heard(probably dry inside) There is not one drop of fuel coming out any of the hard lines-no pressure. I can hand pump fuel through the feed/return hoses, but nothing else. The vacuum shut off valve is not stuck or anything of the sort(the rod inside is very free moving). I should say that the filters are not clogged(its running off a clean tank).
My question is, could it be possible that the cam on the lift pump has worn, or broke?
Causing this problem? Everyone I ask about the internals of the IP usually give the same answer(thats not owner serviceable) I have the feeling the people on the other end of the phone are giggling......Its almost like the internals are a closely kept secret, just as the parts are to fix it.

From what I have been told, only a IP pump from a 75-76 will fit this.

Does anyone know if the lift pump from a 77-85 would fit Mr Benz? Ours doesn't have the primer on the lift pump. The bolt pattern, and mounting look identical.

The other problem is getting the ip off the car, those bottom nuts seem to be very pesky! Looks like I may have to take the motor mount-or the whole oil filter assembly off, to allow clearance for the socket

I'd definitely replace or rebuild the lift pump before removing the IP. Sorry, I can't tell you which lift pump will work. You could gravity feed the IP from a bottle of diesel and see if it runs.

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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

thats what I was doing. I would love to not have to take the ip off. But I can't find a way to get to the lower two bolts on the lift pump, while its still in the car.

Loosen the Spin-on Fuel Fuel Line between the Fuel Supply/Lift Pump and see if you have Fuel coming out; if not you have a Fuel Supply Problem.
Then there is the Fuel Pressure Relief/Over Flow Valve the controls the pressure of the Fuel Supply/Lift Pump.
Long Fuel Pressure Relief Valve/Overflow Valve Thread
Fuel pressure relief valve adjustment - PeachParts Mercedes ShopForum


There is a Valve Kit for the Fuel Supply/Lift Pump (it used to be around $20) you can get from Mercedes and maybe Pelican. Then you need to scrounge up a 5mm O-ring because that does not come in the kit.

However, before ordering any kit I would remove the big 30 or 32 mm Plug on the Fuel Supply Lift Pump and pull out the Spring and if you can the Piston and inspec them. You need to know if the Spring is broken.
It is also not unknow for the Push Rod to break.

Bunch of random stuff from My notes:
Lift Pump Kit Hunter 617.951-952
OM617.951 and .952 Lift pump Repair kit W126.120 300SD W123.133 300D - PeachParts Mercedes ShopForum
Lift Pump kit post #48
fuel pressure - Page 3 - PeachParts Mercedes ShopForum MORE LIFT PUMP STUFF

FUEL DELIVERY DIY (Hunter)
Fuel Delivery: - PeachParts Mercedes ShopForum FUEL DELIVERY DIY
Lift Pump taken apart
fuel pressure - Page 3 - PeachParts Mercedes ShopForum

Lift Pump, Fuel Supply Pump rebuild kit
Anybody know a good Fuel Pump replacement DIY page? - PeachParts Mercedes ShopForum

Lift Pump, Fuel Supply Pump about sanding the Valves has the small O-ring size
Lift Pump Rebuild... - PeachParts Mercedes ShopForum

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84 300D, 82 Volvo 244Gl Diesel

Back to the Fuel Injection Pump itself.

If the Elements (Plungers and Barrels) were starting to get worn out what would happen is it would start OK cold but would have trouble starting when it was hot.

If there was any Water in the Fuel it is possible for Rust to develop in the Element or Plunger or Barrels and what can happens is the Plunger goes up and jams in place and the Spring cannot return it.

You can do this only on an MW type Fuel Injection Pump. Similar to what you would do if you were Drip Timing. You remove the Delivery Valve Holder the Srping, the Centeral Valve and you will add removing the Barrel that the central Valve went into and the Crush Washer.

You can now look down inside and see the Plunger down in the Barrel of the Element. You can watch that as someone rotates the Engine by Hand for you and you can see if the Plunger is moving up and down as it is suppsed to.

If it is not moving remove the Fuel Supply/Lift Pump (about a Pint of Oil is going to come out) and have someone hand crank the Engine and see if you can see the Camshaft Moving. If the IP Camshaft is moving but the Plunger is not your Element Plunger is stuck.
If the IP Camshaft is not moving that is another issue.
It is not unknow for the Camshaft to break but it seldom Happens. I have only seen that happen 2 times in 5 years working in Fuel Injection.
More common is the Drive end Nut or Bolt coming loose and the drive end shears off the Woodruff Key and spins.

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84 300D, 82 Volvo 244Gl Diesel

I believe his IP will have the old style lift pump which cannot be rebuilt...well can but there is no kit available...he will either need to buy a new style or pull one from pick n pull and rebuild that one.


http://www.peachparts.com/shopforum/diesel-discussion/322286-78-240d-lift-pump-valves.html

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The lift pump gasket kit is still available. It is Bosch kit# DGK301 ($14.60 CDN). I bought them 6 months ago form a Bosch IP shop. FYI.. the rebuilt kit for the IP for the W115 300D (75-76) is also still available: DGK128 ($37.25 CDN)

Is this the entirly complete Kit that has all of the Crush Washers including the one for the Lrge Plug and also the small 5mm O-ring?

This is what I have from My previous notes from severa years ago does what you recieved sound the same:

"Bosch FP/K22MW22 Feed pump There is a repair kit for these pumps. Bosch part number DGK301 The kit covers FP?K KE and KS pumps includes more parts than you'll need to rebuild your pump includes springs, copper crush washers, piston seal and check valves. Also included in the kit is the mounting gasket. There is a sediment bowl and prefilter cartridge included in the kit for other applications. Some of these pumps are used in heavy equipment and in the aviation industry. I got my kit overnight from a diesel injection shop I used in the past. Hope this makes the parts easier to track down. Price wise I got it for under $22.00 including shipping and local sales tax."

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84 300D, 82 Volvo 244Gl Diesel

maclaveau- your post with pics is on page 3 of the below Thread:
Refreshing the fuel pump on an OM617 (European spec – non turbo)

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84 300D, 82 Volvo 244Gl Diesel

maclaveau- your post with pics is on page 3 of the below Thread:
Refreshing the fuel pump on an OM617 (European spec – non turbo)

However the Stretch part of the Post is about a Fuel Supply/Lift Pump with the Disc type Valves in it. Not like the ones on the Turbo models

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84 300D, 82 Volvo 244Gl Diesel

I don't know. The original Poster does not have a 240D He said He has a 76 300D (He did not say if it was a Euro or US model).
I looked up the Valve Kit at a Russian Parts site and it has. Item # 428 is the kit and it is the same Number as the Kit that would work on My 84 300D (Part #0000900210, this is the Valve Kit with no O-ring)

http://mb.ilcats.ru/part/class/1/ccode/F/cat/67K/type/617/subtype/910/group/07//

If you want to start from the beginning
Russian Parts site newest
http://www.unitcat.ru/ Home Page

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84 300D, 82 Volvo 244Gl Diesel

Guys if you look in the W123 FSM chapter 07-001 in the non turbo section gives you a nice list of IP + governor + lift pump numbers

You can see the secret combinations there.

@300d_4_me if you don't have access to the FSM (or you can't get the sodding free version on www.startekinfo.com to work for you) then post up the IP number (Bosch number) and I'll look it up for you.

You will probably have a MW pump and a lift pump that looks similar to the one in this thread

Papa's got a brand new om617 IP to play with!

There's information on refreshing both pumps here =>

Refreshing the fuel pump on an OM617 (European spec – non turbo)

EDIT - sorry Diesel911 you've already posted that one! (He's faster than a speeding bullet you know!)

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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!

I spend a lot of time on the fourms as it is easier to talk about fixing Cars then it is to fix them. And, I don't have a Job.

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84 300D, 82 Volvo 244Gl Diesel

Yes, it is the complete kit. "300d 4 me" and I have the same feed pump (no primer on the feed pump itself, it's on the main fuel filter housing).

I gotta say-I didn't think I would get so much feedback on this...THANKS!

I'll try to get some pics, part numbers & etc up a little later today. That is fantastic news about rebuild kits. It may be a little while before I try looking into the bits of the pump while turning.

The car is US spec as far as I know. The pump looks about the same as in that thread. Mine has the altitude adjustment knob on the top plate. I should say that when it gave up on me I went looking on the forums here. I found a very nice thread about cleaning the goo out of old Ip pumps. I ran some acetone (hand pumped) through it. After a few days An incredible amount of junk came out, it was just amazing.

The engine, and trans is not original.
I believe the motor is a 75. As for the trans, it is from a 73ish gas car. The serials confirm it. Im gonna go out here, and get all of the juicy details that makes this special.