Good day installing new IP in "Spouse" - then I had to go and ruin it ! Broken tab. - PeachParts Mercedes-Benz Forum

jbrianfoto · #1 06-01-2014, 07:11 PM

The last of my parts arrived yesterday in the mail - today after church I set out to install a new om603 Injection Pump in my wife's 87 300TD. Piled everything together on my workbench, counted parts, then took it all over to where I keep the car.

New IP with the bags full of new lines, crush washers, VTV, check valve, o-ring. Everything.

I prepped everything that I could before I started installing it in the car. I mounted the lines with brand new crush washers - inserted the IP locking tool (allot easier when the pump is in your hands), rolled on the big o-ring.

How it looked before I installed it in "Spouse"

Having just installed one of these 3 weeks ago, this one went in really easily (and fast) - only took about 10 minutes to wiggle and twist and wiggle some more until it was completely in place. I was able to right away insert all three fastening bolts finger tight, then I screwed in the rearmost fastening bolt (forgot that one on my last install, had to install it with the intake plenum and all lines in the way - not fun).

Clean new IP - ready for final tightening of the three bolts and the left handed center bolt (to 45 NM of torque). Looks sooo nice......until.....

So - I'm tightening the main three bolts when my wrench slips off one of them and I hear a 'snap'. I thought nothing of it, figured my wrench smacked against the power steering pulley or something. I installed and torqued the center bolt. Then I gave everything a good looking at (to make sure I didn't miss anything). Well - I did miss something -

This is a cracked support tab on the drivers side of the IP. cracked thru all the way. Everything else is just fine from what I can see.

Question is; Do I need to take this all the way out and have it welded? Or - since the other two are fine, and I have the rear bolt in place and the support of the center bolt too - do you think I'm ok?

I'm done for the day - ;-(

GregMN · #2 06-01-2014, 07:58 PM

I think that if it doesn't leak oil, you are ok. I have no experience with a 2 tab installation, so maybe someone else would "know" better than I "think".

It begs the question "why did it snap?". I think that the IP and tab should be flush to the block when installed properly.

Maybe you tightened the rear mount first ?

sixto · #3 06-01-2014, 11:58 PM

x2, check that the IP is flush to the block. If not, fix that then see if it leaks.

If the surface between the ribs is parallel to the block mating surface, fabricate a forked tab and spacer to fit over the broken tab and get a longer bolt.

Sixto
MB-less

GregMN · #4 06-02-2014, 12:12 AM

It's possible that the timing adjustment assembly was not in it's slot in the IP body. That would have held the IP away from the block just inboard of the tab that snapped off.

ROLLGUY · #5 06-02-2014, 02:04 AM

Quote:

Originally Posted by GregMN

It's possible that the timing adjustment assembly was not in it's slot in the IP body. That would have held the IP away from the block just inboard of the tab that snapped off.

You took the keyboard right out of my hands before I could type that out

jbrianfoto · #6 07-20-2014, 07:30 PM

Quote:

Originally Posted by ROLLGUY

You took the keyboard right out of my hands before I could type that out

You Both were right, gonna gave to share the Cupie doll.

Sent from my iPad using Tapatalk

nulu · #7 07-20-2014, 09:18 PM

Ive got a good injection pump if you need it, dont know whats it worth, i did have it on a car last year and ran good

jbrianfoto · #8 07-20-2014, 06:55 PM

Quote:

Originally Posted by GregMN

It's possible that the timing adjustment assembly was not in it's slot in the IP body. That would have held the IP away from the block just inboard of the tab that snapped off.

Got the IP out today, finally, and gave it a good looking over. It appears that I had the adjustment screw one slot too high, which causes the outer lip of the adjustment screw to ride against the engine block. When I tightened the bolt on that side, the screw lip acted as a fulcrum and SNAP went the tab. I'm taking it to someone who I trust as a welder. Will post photos of the repair when it's all done.

I'm such a dope.

jbrianfoto · #9 07-20-2014, 07:18 PM

Some photos;

GOOD - the adjustment collar is seated INSIDE of the scallop designed to completely house it.

BAD - Notice collar is ABOVE the scallop - causes the collar to stick out too far and break the corner tab ;-(

Shots of the breakage -

I just hope cast aluminium can be repaired. I would imagine that some extra material will need to be added over the shoulder area, and I'll need to procure a longer Grade 8 bolt to clear everything.

pawoSD · #10 07-21-2014, 10:26 AM

What are you taking those pictures with? Is that a film camera or digital?

jbrianfoto · #11 07-21-2014, 10:42 AM

Quote:

Originally Posted by pawoSD

What are you taking those pictures with? Is that a film camera or digital?

I'm from a family of photographers (grandfather, father) - I do shoot alot of film (up to 8X10) - but these photos were all taken with my iPhone and the Hipstamatic app. It has a film/lens combo which looks just like 2 1/4 film and I really like it.

funola · #12 07-21-2014, 11:17 AM

Quote:

Originally Posted by jbrianfoto

I'm from a family of photographers (grandfather, father) - I do shoot alot of film (up to 8X10) - but these photos were all taken with my iPhone and the Hipstamatic app. It has a film/lens combo which looks just like 2 1/4 film and I really like it.

This is not a Hipster forum. Why not present clear, sharp, color photos instead of bluring it intentionally with an app? Is that shooting oneself in the foot?

Mölyapina · #13 07-21-2014, 11:31 AM

Geez. Who cares what the pics look like? At least I can see all the detail that I need to see... we're just looking at a broken tab, not at microbial life forms on the adjustment screw or something...

ROLLGUY · #14 07-21-2014, 12:04 PM

Quote:

Originally Posted by Jooseppi Luna

Geez. Who cares what the pics look like? At least I can see all the detail that I need to see... we're just looking at a broken tab, not at microbial life forms on the adjustment screw or something...

You see that microbe too! I thought I was the only one to see it in the photo