Hello everyone!

I really enjoy reading this forum and would probably continue just reading it if following problem would not happen to me.

I cannot find any info that could help me fix this problem and it looks that I need help from more experienced people. I know there are a lot between this forum members.

I have a w124 sedan with OM603 engine which I got from my father who died from cancer a month ago, so it is important for me to get this car running.

Week ago when I was replacing belt tensioner and fan visco coupler, I decided to fix an oil leak on IP (M type) which was coming from stop lever.
After reading this: PeachPartsWiki: Injection Pump Stop Lever Oil Leak Fix . I decided to check O-ring and clean overall mess.
I took off washer with no problems, but when taking off the O-ring I pulled the shaft out off its position. I had no problems to put it back in (at least I thought so ).

When I put back everything, I started the engine and it started to run at very high RPM instantly, I could not stop it with key. The stop lever was in down position, so no hope there too. I tried to move it lower but all it did was lowering the RPM a little bit. I managed to pull off the fuel hose that is right after the small fuel filter to stop it in a garage full of black smoke.

I tried to put this lever in "right" position and it seems that it is in only position that corresponds to angles of right stop lever position and also has some movement in this range. I tested the vacuum stop unit with mityvac and it moves the lever fine. When I turn the key, stop lever does not move upwards before starting the engine. Same situation happened the second time I started engine.

As I understand I may have disconnected this lever from something or loosened some spring, but I cannot find a decent schematic or pictures/video of this IP to understand what really happened and how to fix it.

I remember I did few turns of nut that goes around the shaft by mistake before trying to take of washers, but I screwed it back again and tightened well. Maybe this could be problem.

I would appreciate any information, documentation, suggestions on how to fix, test or deal with this problem.


Best Regards,
Vilnis

This happen to someone else several Years ago. Although his went all the way inside.

I think He had to remove some component on the top of the Pump to get at it from the inside. What I remember is that the Stop lever was on the one side or the other near the top near the top.

My Mom died on Sep 8th; I can see how a recent death would a bad time to have to deal major Car trougle.

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84 300D, 82 Volvo 244Gl Diesel

Thanks for the response. My condolences.
Maybe You could give a link or something to that discussion. I think it could help.

I am afraid to take it apart before I don't understand what I am doing.
We had timing chain broken and did almost all the work by ourselves, but we had info and my father also was pretty skilled mechanic. So it went well.
As this is not common problem, I really don't know what to do.

Any information would help.

Shut off valve replacement W124 602/3 300D 2.5

This thread may help

__________________
John HAUL AWAY, OR CRUSHED CARS!!! HELP ME keep the cars out of the crusher! A/C Thread
"as I ride with my a/c on... I have fond memories of sweaty oily saturdays and spewing R12 into the air. THANKS for all you do!

My drivers:
1987 190D 2.5Turbo
1987 190D 2.5Turbo
1987 190D 2.5-5SPEED!!!

1987 300TD
1987 300TD
1994GMC 2500 6.5Turbo truck... I had to put the ladder somewhere!

vstech, thank You very much. This will help a lot.

Maybe someone has an schematic or something like that for this IP? I want to understand better what I will be doing.
Guy called samsen, had the same problem as me. Hope he responds to email.

Make sure to provide provision to kill the engine quickly anytime work on the injection pump shutoff is involved. Usually opening up the breather and a block of wood at hand to stop air going into the engine. This shuts it down fast.

You are right, I should do that. Disconnecting the fuel hose is more frustrating for me and for IP. Thanks.

My sure fire way to stop a runaway om603 is to crack open one or two injector lines (wherever is easiest for you - I get at 'em on the #1 or #2 cylinder up by the injector) - shuts down almost immediatly. I am not a fan of blocking the turbo input - for that to work you kinda need to be prepaired first - I keep a 15mm wrench in the car just in case.

__________________
1987 300TD named Klause
1987 300TD named Spouse
1987 300D named Seabiscuit
1980 300TD names Chloie (now sadly gone)

Yes, there always have to be few ways in case one does not work.

That may work if the runaway is from an IP malfunction. If the source of fuel is via the rings it will not work. Have you actually done that? Please describe how it went. Did you have goggles on? An engine close to redline will have a lot of high pressure fuel squirting out. Does not sound like a pleasant experience. Cutting off the air supply is the quickest way to stop a run away.

__________________
85 300D turbo pristine w 157k when purchased 161K now
83 300 D turbo 297K runs great. SOLD!
83 240D 4 spd manual- parted out then junked

the injector line nuts are 14mm on the 603...

they are 17mm on most older MB diesels.

this sounds like a messy method to attempt shutting down a vehicle...

the BEST method to shut down a runaway diesel that is not responding to the stop lever, or the key, is to have a halon or CO2 fire extinguisher to blast into the intake...

#2 method would be a block of wood to choke the air flow to the intake.

#3 would be interrupting the fuel flow... either employing a valve in the fuel line, or cutting/ otherwise interrupting the flow... I'd not wanna try loosening line nuts on a motor spinning 5000rpm !

__________________
John HAUL AWAY, OR CRUSHED CARS!!! HELP ME keep the cars out of the crusher! A/C Thread
"as I ride with my a/c on... I have fond memories of sweaty oily saturdays and spewing R12 into the air. THANKS for all you do!

My drivers:
1987 190D 2.5Turbo
1987 190D 2.5Turbo
1987 190D 2.5-5SPEED!!!

1987 300TD
1987 300TD
1994GMC 2500 6.5Turbo truck... I had to put the ladder somewhere!

I want to thank everyone that responded and helped me.
My Benz is now running fine.
Thank You guys! Would not have done that without a help.