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Old 05-22-2014, 06:01 PM
GregMN GregMN is offline
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Join Date: Aug 2009
Location: MN
Posts: 1,253
This is from memory, but I just did it a week ago.

You have to remove the pump.

Set the crank to 15 degrees after TDC. Turn clockwise by hand.
Remove the viewing port plug on the IP
Use a mirror and light to check for the timing ridge. If it is in the center of the window, then the timing is correct. If not, proceed.

Remove the intake manifold
Release the fan belt tension.
Remove the upper radiator hose
Remove the power steering pump pulley
Remove the vacuum pump
Disconnect the fuel lines to the IP
Disconnect the hard lines that go to the injectors. It will be easier if you remove them all together.
Disconnect the fuel return line from the engine side of the IP
Unplug the fuel control valve electrical connection
Unplug the IP harness on the PS of the engine compartment
Remove the center bolt in the timing gear. IT IS LEFT HAND THREADED.
Remove the chain tensioner. PS of the block, inline with the timing chain path.
Remove the rear IP mounting bracket to the block
Remove the 3 mounting bolts
Remove the IP to the rear and up and out. Try not the touch the battery cable connection on the starter when doing this. It would not be a bad idea to block that connect off with something non-conductive.
Retrieve the timing adjustment assembly. It will still be attached to the block.

Turn the pump until the timing ridge is in the center of the viewing port.
Lock the pump timing in place.
You can purchase a tool for this job or make your own : http://www.peachparts.com/shopforum/diesel-discussion/354302-diy-ip-timing-lock.html
Reinstall the pump as far as:
make sure the IP timing adjustment assembly is in place and the head is in the notch properly
the pump shaft splines are fully engaged in the timing gear and the center bolt is in place
the 3 mounting bolts are installed and holding the pump in place, but not tightened yet
the chain tensioner is reinstalled

At this point I rotate the crank 2 twice by hand and check the timing of the IP. If it is OK, then I finish the install.

Do not forget to finish tightening the center bolt on the timing gear.
__________________
Greg
2012 S350 BlueTEC 4Matic
2007 ML 320 CDI
2007 Leisure Travel Serenity
2006 Sprinter 432k
2005 E320 CDI
1998 SLK230 (teal)
1998 SLK230 (silver)
1996 E300D 99k, 30k on WVO
Previous:
1983 240D, on WVO
1982 300D, on WVO
1983 300CD, on WVO
1986 300SDL 237k, 25k on WVO (Deerslayer)
1991 350SDL 249k, 56k on WVO - Retired to a car spa in Phoenix
1983 380 SEC w/603 diesel, 8k on WVO
1996 E300D 351k, 177k on WVO

Last edited by GregMN; 05-22-2014 at 06:13 PM.
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