1990 300d 2.5td
I broke 2 of the delivery valves off in the injector pump. There is about 1 thread left on the valve and the rest is in the pump. My mechanic says he may be able to remove whats left of the thread from the pump with an easyout or something like it.

Does anyone have any experience with this?

It seems my options are either replace the whole pump or see if the threads can be removed. The only problem with option 2 is possible crossed threads and getting junk in the injector pump. Either of these 2 conditions and i still have to pay for the work done and im still out a pump.

Anyone out there have a used injector pump?

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VegStew
1983 300SD 70,000 WVO Powered miles
1990 300D In driveway with Head Off - Cracked

It would be helpful to know how they were broken. If it happened when you were removing them and they broke because the rataining clamp was not removed and the housing did not crack at the screw that holds the retaining clamp you sould be able to replace the Delivery Valve Holders (if the mechanic can get them out with no damage). If they were broken off due the tightening them too much the threads in the aluminum Fuel Injection Pump Housing could be pulled/deformed.
Either way replacing the Delivery Valve Holders with new or used ones is the cheapest way to go.
Your Fuel Injecting Pump dose not look like the one in the picture (the only pic I have) I just used it to idenfify the Delivery Valve Holder for naming purposes. (This pic is for a 617.952.)

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84 300D, 82 Volvo 244Gl Diesel

If He cannot get them out or you need to get another pump the choice is one form the junk yard or fixing yours. If they fix yours they are going to want to do the whole rebuild on it (they have to warrant it). A junk yard pump would be less but still cost.
There is a way to burn out the threads with a machine that used to be called I believe an EMD machine (info from about 20 years ago they most likely have something better now, updated). What the machine dose is the electrode is hollow and coolent runs through it so that it only burns in the area the electrode touches not overheating the parts around it.
The Fuel Injection Pump would need to be removed and it would be helpful to have at least 1 delivery valve holder for them see so that they do not burn down too far. You would also have to replace the delivery valves themselves if they get altered during the burning. It is a precision machine that dose the job not something hand held.
Without giving your exact address what State and City are you located in?

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84 300D, 82 Volvo 244Gl Diesel

The delivery valve holder is what broke. The threads that go into the sleeve are broken off below the rubber o ring and they are stuck in the injector pump.

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VegStew
1983 300SD 70,000 WVO Powered miles
1990 300D In driveway with Head Off - Cracked

I don't see that there is much left for an Ezie-out type tool to grab onto. And if they broke from over tightening they are wedge down pretty hard.
It would not hurt and not cost anything to call a Bosch Fuel Injection shop. It could be they have some special tool to deal with this type of situation!

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84 300D, 82 Volvo 244Gl Diesel

Im in oakland ca.

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VegStew
1983 300SD 70,000 WVO Powered miles
1990 300D In driveway with Head Off - Cracked

VegStew, remove the pump from the car and take it to Pacific Fuel Injection in SSF. Gus Pfister is likely the most qualified person in the US to repair your IP.

Sixto
87 300D

2nd for Gus.

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Terry Allison
N. Calif. & Boca Chica, Panama

09' E320 Bluetec 77k (USA)
09' Hyundai Santa Fe Diesel 48k (S.A.)

I've never taken an IP off a mercedes before. Just on a mitsubishi.... Looks quite different and from what i've read so far requires special tools.
DAG NABIT
$500 for possibly getting the messed up threads cleaned out. If that doesnt work, then i still need to pay for a rebuilt pump.
So far im quoted $1000 from fastlane, $1500 from allmercedes. My indy said $1500 for removal and install of a new pump. Allmercedes quoted me $750 for that.
How do these quotes sound?
Am i right about removing this pump? Special tools etc?

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VegStew
1983 300SD 70,000 WVO Powered miles
1990 300D In driveway with Head Off - Cracked

The only special tool you need is a locking pin to keep a reference between the IP and timing chain. Other than that, all you need are basic hand tools.

Sixto
87 300D

Sounds like it might be better to spend the money on a rebuilt or take your pump to that guy the other member recommend. Changing the pump out is not a difficult job. $1500 for the Indy to remove and install is too much.
If you had the manual you could read up on the job and see if it is something you could handle yourself.

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84 300D, 82 Volvo 244Gl Diesel

$1500 is only good if it includes a pump.

3rd for Gus, he should be able to full rebuild your pump for somewhere around $1k if necessary, and it will be as good as new. From what you describe I can't tell if your pump is easily fixable or not.

Simply R&R'ing the pump is about a 4-5 hour job if you know what you're doing. Few parts are needed (couple of gaskets & seals) so it's mostly all labor. Not many indy shops charge over $100/hr, so anything over $500 for labor would seem a bit much (but you are in the Bay area, so who knows!). $1500 to install a rebuilt pump (for labor, misc parts, AND the pump) would be reasonable.

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Dave
Boise, ID
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