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

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

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).

Is that DGK301 the same as DGK301H(the h kit has a later style primer with it)?

I do not know.

I have been eyeballing that one on Ebay also. I copied the Pick to My Computer and enlarged the Pics.

I cannot see any Valves or the O-ring in the Kit but it appears to have new springs and all of the Crush Washers.

I searched on the internet some and can't find a site that tells you what is supposed to be in the kit.

I also did not look up and see if the Hand Primer part number is the correct one.

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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

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

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