My five month odyssey of rebuilding the SD underhood is (hopefully) finished!!

Replaced the following components:

Cylinder head
Cylinder head bolts
Exhaust valves
Manifold studs
Prechambers
Valve guides
Valve seals
Head gasket
Starter
Water pump
Belts
Upper hose
Oil cooler lines
Oil filter housing gasket
Alternator tensioner
Differential change to 2.88
Downpipe
Removal of resonators
Jet-hot exhaust manifold
Set injectors all to nominal spec.
Set valves all to nominal spec.
Injector return lines
Crossover tube from water pump to head
Boost line from banjo fitting to overboost valve
Tapped exhaust manifold and plugged EGR port
Air filter
Valve cover gasket
Valve cover breather hose
Set injection timing to 15°ATDC, precisely, using RIV tool.

I started it tonight, in the garage. Everything looks good. No leaks!

Tomorrow it goes out for a drive.


One question remains:

Using the RIV tool, I can achieve 16° after top center. The IP will not move any further toward the engine. I'm not overly concerned about 1 degree, but has anyone found that the range is insufficient?

The cam is running 2.5° late based upon the marks on the tower.

Does this require moving the pump by one spline..........or would this cause far too much movement in the opposite direction?

Unfortunately I have no answer to your question, but I just wanted to offer a big slap on the back for a job well done, you've just about been everywhere in that car, haven't you! Good luck on the test drive.

peace,
sam

__________________
"That f***in' biodiesel is makin' me hungry."

1982 300TD Astral Silver w/ 250k (BIO BNZ)
2001 Aprilia SR50 Corsa Red w/ 5.5k (>100 MPG)

No answers from me either. I usually look to you for those! Just wanted to say congratulations.

__________________
B
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1983 300SD

If you are out of range of motion, couldn't you technically move the IP forward/back one on the splined input shaft?

Just an idea...I presume you already thought of that

Glad the SD is done....you seem to have really put in a lot of time into it.

Lots of shiney new parts!

Yes, that's what I was thinking as well. But, the question is whether the number of degrees, per tooth, is less than the available range of the IP. I'd like to hear from someone who has done it this way and gained the range.

The pump doesn't provide much angular rotation............so there would have to be quite a few teeth.

I've got two sitting in the garage, want me to count the teeth?

They are pretty fine...

No, don't bother. Let's wait and see if anyone has removed and replaced the pump with the timing off by one tooth. Someone has done this. BHD would probably know.

Did you have the pump out?

I was considering it to change the gasket when the oil filter housing was out. But, with the camshaft out, I didn't want to push my luck regarding getting everything back to spec.

So as I understad you are getting 16 degrees at the mechanical limits of the adjustment in the direction it needs to go and you need an additional degre or so.

In this case I would move it by one spline to get it back into the range the IP is able to rotate...I don't have the means to determine exactly how much movement you have via the IP but I am certain its sufficient to clock it by one spline to place it in the range you need.

You have gone this far....may as well take the steps to do this one right.....I preffer to have a proper setting fall sfficiently in the center of the range to allow for adjustment now and in the future should the need arise.

__________________
Proud owner of ....
1971 280SE W108
1979 300SD W116
1983 300D W123
1975 Ironhead Sportster chopper
1987 GMC 3/4 ton 4X4 Diesel
1989 Honda Civic (Heavily modified)
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Section 609 MVAC Certified
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"He who fights with monsters might take care lest he thereby become a monster. And if you gaze for long into an abyss, the abyss gazes also into you." - Friedrich Nietzsche

I'm getting 16 degrees at the maximum limit of the IP toward the engine. The spec is 15 degrees. So, I'm not going to bother with it for one degree.

But, if the pump was reset by one spline, would it still be in range, or would it be outside of range on the high side??

How much adjustment, in crankshaft degrees, is available on the IP?

Also, the IP seems to have more rotation capability on the three screws, but it hits a hard stop somewhere near it's center or back end. Any idea what causes this hard stop? In reality, it can't go much more anyway because the throttle linkage will interfere with the hard line to the #4 injector.

I don't see how it is possible to remove that rear support bolt with the oil filter housing in place??

I cannot even see that bolt from below.

I can remove the two screws on the bracket but there is no way to get to the upper bolt that is secured to the IP.

From your previous comments, you can't remove the IP with the little bracket attached, correct?

Do you have the rear support bracket attached...that may be the stop you see..or potientially one of the three slots is hitting the stud before the others...

It up to you...but if you are not adverse to the work to clock it 1 tooth you will gain clearance there....

What was the seting with the RIV tool? I know its different than the other timing methods, if it was 16 I would like to see that 16 somewhere in the middle 1/2 of the adjustment range and not 1 degree off a hard stop.

Do I know how many crankshaft degrees is availible at the IP? no I never really looked into it before nor an I sure where to find that info.

__________________
Proud owner of ....
1971 280SE W108
1979 300SD W116
1983 300D W123
1975 Ironhead Sportster chopper
1987 GMC 3/4 ton 4X4 Diesel
1989 Honda Civic (Heavily modified)
---------------------
Section 609 MVAC Certified
---------------------
"He who fights with monsters might take care lest he thereby become a monster. And if you gaze for long into an abyss, the abyss gazes also into you." - Friedrich Nietzsche

The setting was 16 degrees After TDC with the pump on the stop as close to the engine as possible.

I could, I suppose, loosen the pump and rotate it all the way retarded and read the RIV tool. Then, if we know the number of splines on the pump, this can be converted to degrees/spline. The number of degrees on the crankshaft would need to be divided in half to come up with the range on the pump. If this value is greater than the figure for degrees/spline then the movement of one spline would work.

I have my doubts, however. I can't imagine that the engine would provide more than 10 degrees of adjustment. This means 5 degrees at the IP. This means that the number of splines has to be more than 72.

Does the IP shaft have more than 72 splines? I would sincerely doubt it.

I just did it at the yard today...in the rain...

Use a long 13mm wrench and it seems to reach it just fine.



You can only get it from above.