I need to replace the ip diaphragm in my 240d and was wondering if this is just a straight replacement? Do i need to set any kind of preload on it? I know the vacuum leak could also be the poppet valve stuff so i'll replace the o-rings as well.
john

There is several thread on what to do.

There is a special tool for setting the shims on the Diaphragm but as far as I can remember most people have taken it apart carefully keeping the shims together and getting them back to where they came from.

There is a tubular end on the Diaphragm that has a cross drilled hole in it. inside of that there is some shims and one or 2 springs. You need to get those back to where they came from.

There is also shims other places but they are more obvious.

Best to find the threads and or take advice from some one who has done it before.

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84 300D, 82 Volvo 244Gl Diesel

I would do a thorough visual inspection of the diaphragm with a flashlight before attempting to remove it.

Hopefully your leak will be in the rear cover assembly, which can be remedied sitting at a table rather than hunched over the fender.

Let us know what you find.

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1972 Mercedes-Benz 220D
www.mezzo200.com

I will definitely check the diaphragm before I remove. I have done a search on the replacement and there are quite a few posts that don't mention measuring anything. It seems like they just take out the old one and put the new one in. I was just wondering if that was indeed what they did and it worked? The other thing that never gets mentioned is if there is a gasket were the housing comes off.
john

Here is the Factory Service Manual:
Mercedes-Benz Model 114/115

At that page, click on "07.1 Diesel Injection System".
Scroll through the sub-function groups inside the white box until you get to "215 Replacing Diaphragm..."

Also, there are other directions there that may be helpful.

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1968 220D, w115, /8, OM615, Automatic transmission.
My 1987 300TD wagon was sold and my 2003 W210 E320 wagon was totaled (sheds tear).

There is no gasket between the injection pump and the rear housing.

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1972 Mercedes-Benz 220D
www.mezzo200.com

In the pic from the instructions the parts circled in red have to be kept together and go back in the same order as they came out of the old Diaphragm.

All of those parts in front of the Diaphragm go inside of the Tube attached to the Diaphragm.

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84 300D, 82 Volvo 244Gl Diesel

finally got around to changing the diaphragm. well i finally started and then thought i would check with you guys before i did anything too stupid. I got the rear cover and large spring out easy. this area had quite a bit of fuel/oil in it. you can't really see it in the photo but there is a big rip at the bottom of the diaphragm (red circle). the cam in the rear cover plate was nice and clean no wobble or anything. the o-rings were hard as rocks and i actually found some that were pretty much the right size. the center hole was just a little small so it was a tight fit but it all went back together. ok so my question is do i have to remove the back of the ip to get to the clip that holds the diaphragm in? i mean i can see what needs to come apart but its about a quarter inch inside. if i do have to take the back off what is the slotted bolt and locking nut? (green circle)
john
p.s. thanks for the link Shortsguy1 that helped a lot. i'm just trying to avoid screwing the pooch here.

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