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  #1  
Old 08-03-2003, 10:22 PM
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Question '87 603.960 Injection Pump, not pumping

My '87 300D-turbo ,603-960, 6cyl, 3ltr., fuel pump is not pumping fuel. If the fuel pump is removed from the Injection Pump it pumps fuel when the pump lever is pushed by hand.
When watching the cam that drives the fuel pump while the engine cranks it does not turn.
I don't know it the injection pump is turning or not but I suspect not.
Hopefully there is only a problem with the a woodruff key or the injection pump drive system or something else simple....maybe not.
Before I tear into anything I'm looking for info and diagrams on the injection pump. I have the MB shop manual on CD that has timing instructions but there are no diagrams of the internals of the pump and only one of the external timing gear. The pump is a model: PES 6M 55C 320 RS157, but they are all probably similar in function
I've surfed the web but find no info/diagrams of bosch diesel injection pumps. If someone has diagrams, can make a scan and post/email them that would be great.
There is a Bosch book out there for the PES injection pump series one of which I'll have to locate if I can't find help.

If it turns out to be an expensive or fatal problem I may need advice on finding a used injection pump or a reliable/reasonably priced rebuilder.
thanks

Last edited by jhh322; 08-04-2003 at 10:45 AM.
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  #2  
Old 08-03-2003, 10:37 PM
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smoke gets in your eyes
 
Join Date: Jun 2000
Location: SF Bay Area
Posts: 19,744
603.960 perhaps? Crank the engine with the oil filler cap off and see if the cam is spinning. It'll be less than a good thing if the cam isn't spinning either. Then pull the timing port plug (17mm head bolt aft of the fuel pump). Use a mirror to see if the timing wheel is spinning. If there's nothing to see, set the crank to 15 ATDC #1 and feel for a lug on the timing wheel. If nothing, give the crank another full turn to 15 ATDC #1 and try again. In fact, you can probably rest a stick against the timing wheel to check if it's turning. I don't know if the pump is driven off the IP's main shaft or another shaft. If it's the same shaft then the test will tell you nothing you don't already know.

Sixto
95 S420
91 300SE
87 300SDL
83 300SD
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  #3  
Old 08-04-2003, 10:56 AM
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603.960 it is !
Hopefully the camshaft turns and the engine TC isn't broken.
Do you know if the IP runs off the TC and if the 3ltr is known to bend valves if the chain is stretched or broken ?

Thanks for the input Sixto
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Old 08-04-2003, 02:59 PM
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smoke gets in your eyes
 
Join Date: Jun 2000
Location: SF Bay Area
Posts: 19,744
The 603 main chain links the crank, cam and IP. The vacuum pump is driven off the IP timer sprocket. A shorter chain links the crank and oil pump.

You'll bend valves in a 603 if the chain breaks. The engine will sound different when cranking if the cam isn't spinning. You would have noted that in your message so the problem is probably in the IP or timer.

Sixto
95 S420
91 300SE
87 300SDL
83 300SD
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  #5  
Old 08-06-2003, 11:44 AM
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Latest update. The timing chain jumped the IP sprocket and there are some plastic pieces floating around..probably chain follower damage. After looking at the shop manual it looks like a major job to tear-down and remove the timing cover to access tensioner rail and followers.....intake, head, etc......my expensive bad luck.
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