OM603 Injection Pump Installation
 

Dear Crew,

Today I removed my OM603's IP in order to put in a new O-ring after it started leaking. Needless to say, after battling for over an hour, I could not get the pump to thread again with the timing chain gears to get it installed.

I did everything by the manual....locked the pump with the MB tool, released the chain tensioner, set the timing to 15deg ATDC, etc. But I wiggled the pump and could not get it to thread through....is there a simple trick that I am missing? Cleaning the teeth with circuit cleaner? Using grease?

Any help would be greatly appreciated!

Are you using an "assembly basket" tool to hold the timing device in it's proper place while you install the IP from the back side?

Thank you for your prompt reply. I am not using an assembly basket. Is there a way to do it without this tool?

In theory it's might be possible for you to mount the locked IP with its three bolts, in the position with its adjuster at the middle of its range, to the block. Then while keeping the crank from turning off 15 degrees ATDC if there was enough slack muscle the timing device onto the splined nose of the mounted IP, possibly!

Or if someone could hold the timing device in the position the "assembly basket" is designed to, while you positioned the IP, maybe!

I have never used the basket.

I just reach around with my left hand and position the pump with my right hand and push the gear on the splines of the pump shaft. I have never had the slightest problem or any resistance.

Make sure that the pump timing adjuster is in it's slot on the pump correctly.

I had to fuss with it for 20 minutes to get the splines engaged, and I WAS using the basket. I'd not try to do it without a basket. You just want oil on the splines. I just put the IP in place and slid it into place in the timing device by turning it advanced and retarded until I found the splines. Get it more or less in the center and then you can adjust the pump with the adjuster after it's bolted up.