Sourcing parts for 617NA fuel pump rebuild

[Fulcrum525]

I am going to be embarking on a fuel pump rebuild for my naturally aspirated Euro 617 in the next few weeks so i'm just starting to source the parts now.

I know what I need in the sense of 3 o-rings and 3 copper washers but I don't know what sizes I need.

My biggest headache is finding the tiny o-ring that needs to be installed on the inner shaft. The best I can find thus far is that it might be the same ID 5mm ID x 1.5 mm CS as on the MW pumps. (Source Lift Pump Rebuild...)

The second headache is the big 30mm copper washer for the hexagonal plug. Most threads here don't give any specs for any of these.

Refreshing the fuel pump on an OM617 (European spec – non turbo)


For the rest I do have one of these generic o-ring kits which I'm hoping will have the two sizes for the valves and I should be able to figure something out for the copper washers (I have a bunch left over from oil changes which i'm hoping will fit, otherwise maybe a trip to Ace Hardware)
https://cnc-specialty-store.com/o-ring-kits-metric-orings/metric-o-ring-kit--p-g-metric-o-rings-japanese-standard-kit?gclid=EAIaIQobChMIiJftubvv2AIV2AeBCh3vcgXZEAYYAyABEgKY1_D_BwE

Any pointers will be most appreciated.

[OM617YOTA]

You're doing it the hard way, the rebuild kit includes everything. PN DGK301. Includes the ginormous copper seal, the teensy shaft O ring, the other copper seals and O rings, everything. If you haven't done your primer pump recently, do that too, it's not included in the kit.

A paperclip or a safety pin with the tip bent is good for getting the teensy O ring out. Or a dental pick. Obviously make sure you lube the shaft with engine oil before you put it back through.

The huge 30mm or whatever hex nut is very thin. I ground the taper off the inside of my socket before use, otherwise that taper reduced the engagement area to almost nothing and hugely increased the chances of doing damage while applying force.

I also bolted the lift pump body down to a board, which was then clamped in a vise. Much easier and safer than trying to hold the pump while torquing on it.

[300 Super D]

Yep, just buy the real kit or suffer endlessly.

[Redrock240g]

Are you looking to rebuild the 2 bolt pump (type M)?

I am look to source the same parts and there doesn't appear to be a kit. I have a call into a local injection shop and they are hopefully going to be able to help.

[Fulcrum525]

Originally Posted by Redrock240g

Are you looking to rebuild the 2 bolt pump (type M)?

I am look to source the same parts and there doesn't appear to be a kit. I have a call into a local injection shop and they are hopefully going to be able to help.

Yes that's the one. The part number that OM617Yota posted earlier (DGK301) looks to be a Bosch part number. I've had trouble finding a Bosch supplier in my area in the past but I'll try again later on today.

[Redrock240g]

You might read this thread, it looks like that kit is for the 3 bolt with roller vs 2 bolt with plunger.

http://www.peachparts.com/shopforum/vintage-mercedes/370355-75-240d-om616-lift-pump-part-numbers-parts.

[greazzer]

There is a kit for both style pumps.

The only problem with the 2-dog eared styled pump and its kit is that no small O-ring is provided for the shaft.

[Fulcrum525]

Originally Posted by Redrock240g

You might read this thread, it looks like that kit is for the 3 bolt with roller vs 2 bolt with plunger.

http://www.peachparts.com/shopforum/vintage-mercedes/370355-75-240d-om616-lift-pump-part-numbers-parts.

The pictures are not available in the thread but I checked elsewhere and yes it looks like DGK 301 is for the turbo style pump (3 mounting bolts instead of 2)

Originally Posted by greazzer

There is a kit for both style pumps.

The only problem with the 2-dog eared styled pump and its kit is that no small O-ring is provided for the shaft.

I was looking at a company called Hercules's Bulldog last night and it looks like they have the small o-ring. I will confirm later if it is the correct size.

[Redrock240g]

Originally Posted by greazzer

There is a kit for both style pumps.

The only problem with the 2-dog eared styled pump and its kit is that no small O-ring is provided for the shaft.

Is there a pn for that kit?

[BillGrissom]

For my 1985 3-bolt lift pump (OM617.952 engine), I bought the kit off ebay (~$15). I recall it didn't have the shaft O-ring (wrong PN kit?), so I just went to my HF Viton O-ring kit. Viton resists even gasoline, so should be OK for diesel or even bio-diesel. I used my HF O-ring pick set to remove the old O-ring. HF also has copper washer kits, but I recall the kit had them. Otherwise, I recall the kit is 2 plastic check-valve "plugs", though my originals looked fine (appears nylon which is tough). Buy the mounting gasket from P-P since not in the kit. Other than the shaft O-ring, it didn't appear that any parts in the lift pump age enough to need replacing.

[OM617YOTA]

Ruh roh! I was unaware there was a 2-eared pump, the PN I posted above was for the 3-eared pump.

I have no input on parts for the 2-eared pump, zero experience there.

Although if the shaft is the same, it might be worth getting the rebuild kit for the 3 eared pump to get the shaft O ring. The kit is relatively inexpensive, how long are you going to take to find the O ring on it's own? My rebuild kit did include the O ring, and I believe the mounting gasket as well.

[greazzer]

Yes, both have a kit #. If you look on Army's thread on rebuilding the "M" style "Euro-Pump), i.e., the 2 dog eared / 2 bolt style, I think he references the kit #. If not, when I get a chance I will look for one in my unorganized parts bin. It's a MB kit and I believe there's only a dealer kit / dealer part # for the 2 dog earned style one.

As for the 3 dog eared style / 3 bolt flange type, you can buy Bosch IF you can find them. I buy every single one I can find. They are NLA and what you will find is NOS. You can buy an aftermarket kit although I suspect its overall quality.

The 2 styles of pumps have different sized shafts, so the O-rings are different. I think one is 7mm and other 6mm, but I could be wrong on that. Just going from memory ...

[Fulcrum525]

Originally Posted by greazzer

The 2 styles of pumps have different sized shafts, so the O-rings are different. I think one is 7mm and other 6mm, but I could be wrong on that. Just going from memory ...

I actually.have three of these pumps at home.

One was on my original 300GDs injection pump which I swapped out from a Euro 300D injection pump. (There was no change in performance which showed that the original IP was fine) And the 3rd is on a spare 617NA engine that I have which came of of another Gwagen.

I can measure the diameter of one of the shafts in a few hours when I get home from work.

[Redrock240g]

Originally Posted by greazzer

Yes, both have a kit #. If you look on Army's thread on rebuilding the "M" style "Euro-Pump), i.e., the 2 dog eared / 2 bolt style, I think he references the kit #. If not, when I get a chance I will look for one in my unorganized parts bin. It's a MB kit and I believe there's only a dealer kit / dealer part # for the 2 dog earned style one.

As for the 3 dog eared style / 3 bolt flange type, you can buy Bosch IF you can find them. I buy every single one I can find. They are NLA and what you will find is NOS. You can buy an aftermarket kit although I suspect its overall quality.

The 2 styles of pumps have different sized shafts, so the O-rings are different. I think one is 7mm and other 6mm, but I could be wrong on that. Just going from memory ...

GZR,

In the thread by "Army" the photo with the part number for the "M" style doesn't appear. So if you have it I think there would be at least two of us very appreciative (guessing others in the future).

I called a dealer early on a the poor guy sounded lost and didn't know the difference between the hand pump and lift pump. But if I had a part number that would be awesome, full inclusive?

[Fulcrum525]

Originally Posted by Redrock240g

GZR,

In the thread by "Army" the photo with the part number for the "M" style doesn't appear. So if you have it I think there would be at least two of us very appreciative (guessing others in the future).

I called a dealer early on a the poor guy sounded lost and didn't know the difference between the hand pump and lift pump. But if I had a part number that would be awesome, full inclusive?

Dealerships and Euro part numbers generally don't get along and sadly unless they really know there stuff most part counter guys are flumuxed with the older technology (I.e anything older then ten years)