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I got the pump in today, it went pretty smooth. I threw the old pump back in got engine to 15° ATDC, removed it and got the tang lined up dead center on the new pump. It wouldn't stay so i took a bolt that fit snug in the hole and cut a slit dead center across it. How far should the shaft of the pump mesh into the splines on the sprocket? I felt it mesh and push in a bit but from the front side of the sprocket there is still at least 1/2" of splines showing. Just wanted to get a second opinion on that. Also i need help understanding the the routing and function of these fuel lines. Feed/ return etc...will i be able to make this work with the 606 filter housing? I looked at some diagrams but still cant find exactly how to route these lines to the 603 pump.

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Ok so i got everything hooked up and started to get the system primed. I am getting fuel to the filter housing, fuel to the banjo on the pump, fuel back out of return line but no fuel out of the delievery valves. I did many 20 sec cranking sessions with good cooldown intervals. I tried putting pressure to my fuel jug, vacuum to return line and even bypassing the filter and going right from the fuel pump to the banjo on the pump. I tried WOT while cranking. Just can't seem to get fuel out of delievery valves.

I don’t know the 606 fuel supply system, only the simpler 603 system.

Are you cranking with the injector lines loose to facilitate purging air?

If you apply vacuum to the shutoff actuator, does the stop lever go down? If so wire the stop lever as far vertically as possible. If not, further discussion warranted around a possibility that the stop mechanism is jammed.

Crank for a few seconds with the return line pinched. Does that help?

Be ready to cut fuel supply to the IP quickly. The darn thing might catch and run wide open if there’s something wrong with the IP.

Sixto
98 E320s sedan and wagon

I am cranking with injector lines loose, the stop level goes down with vacuum applied. I did crank with return line pinched, nothing.

What I don’t see in your picture is how the return line from the IP is routed to the filter block. There’s a special banjo bolt just ahead of the throttle bell crank of the IP. The hollow bolt had a spring loaded ball as a pressure relief valve. Pinching the return line should have tested this but maybe something’s not hooked up properly. Or the 606 has a fuel cutting device I don’t see. So...

This is easy for me to suggest from as far away as I am and all I have invested in your project but the next thing I’d do is bypass the big filter; that is, route fuel directly from the lift pump to the IP. Run a hose from the top fitting of the lift pump to the forward most fuel fitting of the IP.

Sixto
98 E320s sedan and wagon

I tried that i went from lift pump to the banjo on ip completely bipassing filter. As for return i went from the banjo on the other side of pump right next to throttle lever up to filter housing right next to where injector return hooks into. While cranking return spews a constant stream of fuel. It appears fuel is going in and returning but not going to the delievery valves

Do you have a standard banjo bolt on the return line AT THE IP, or do you have the special orifice "overflow" valve installed? If you have a standard banjo fitting, that's your issue, you'll never build any pressure in the IP's fuel rack. The correct orifice valve looks like a banjo bolt, but has a very small drilled orifice on the side instead of the normal hole. It also looks like it has a ball bearing pressed into its head.

Yes the head of the bolt has what you described. A ball pressed into the head

I just swapped out the fuel lines for some clear line. The feed to The filter housing, the feed out of filter housing into the inj pump and the return out of inj pump all flow while cranking without any air bubbles what so ever.

What's the history of the injection pump you're using? Is it a known-good pump? If the fuel rack is full and the orifice is installed to build pressure, the pumping elements should be doing their thing.

If the IP sat for a long time, or it was from a WVO vehicle, the internal parts of the fuel rack could be gummed up or seized.

I got the pump off ebay, only description that was given is that the pump came off an om603 and was removed from a "perfectly running engine". I looked over all screws on the access covers and i can see marks on the flatheads where the covers were torqued on but no marks indicating anybody removed any of the covers. So far i do not see any leaks from anywhere on any of the pumps seals/gaskets. Also i did not smell or see any traces of wvo.

Solved the issue. I took the little shutoff actuator canister off and had a peak in there. I cycled the stop arm and quickly seen that the piece that the shutoff arm makes contact with that moves foward and back was hung up in the stop position. I took a flathead and cycled it foward and back a couple times and tapped the starter with it in the foward position. Shot fuel from delievery valves 8 ft high.

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So after i solved the no fuel issue i called it a night. I came out today and started to bleed out air at the injectors and got it to run but noticed #2 wasnt getting fuel. I pulled the delievery valve out along with all the workings to it. I orientated all pieces EXACTLY how they came out. I cleaned everything and threw back together. Still wasnt shooting fuel out. I decided to pop side cover off just to take a peak. The arm circled in pic was not in its track. It was next to it so i popped it back in. Cranked again still no fuel so i decided to switch components from delievery valve 1 to narrow down which was the issue. First i switched the pieces i have labeled 1-5 from #1 into #2, and put #2 components back into #1. Nothing. I then switched the one i have labeled 6. The issue moved to #1 once i did that and #2 was now getting fuel. What is failing on the piece i have labeled 6?
Fuel is bypassing right thru the dead delievery valve and supplying the rest. And even on the dead one when i unscrew it after priming system it's full of fuel like other good ones. Losing my mind!

Some light reading:

http://www.peachparts.com/shopforum/diesel-discussion/368432-delivery-valve-o-ring-problem%3B-car-clacking-loud.html

5,5 & 7mm element, difference here (filmclip)

Sixto
98 E320s sedan and wagon

I know i didn't damage anything because the problem follows which ever delievery valve i put the component labled #6 into