Oil leak from bottom of IP, '93 W124 300D
 

Now that I have cleaned up my fuel leaks from the IP and stop lever I have noticed that the black stuff on the bottom of the IP is still there.

I have cleaned the IP off several times while hunting down leaks and preparing it for the O-ring and pressure valve seal replacements so the oil on the bottom is an oil leak for sure.

Could I just tighten the bolts on the bottom or is it realistic for me to be able to remove the bottom plate and replace the gasket(assuming there is one there)?

I don't know anything about the IP internals so I definitely won't be taking it apart until I know for sure.

I guess the oil could be coming from somewhere else but it definitely looks like the oil is seeping "up" from the bottom plate of the IP.

I am chasing the same leak; in my case it is the side cover plate that is leaking. Thats a good thing since I dont think I could replace the bottom gasket without removing the pump. The gasket is hardened and one of the screws was missing. I called a Bosch service center and they are dropping off the gasket at the local general store when they drive by next... top that Bryan!

I have this same leak you speak of. Let me know what you find.

There have been quite a few discussions of this issue over the years - try a search.

Most everybody agrees that the only way to change the bottom gasket was to remove the IP - but there was one person here that claimed he was able to replace the gasket with the pump in situ.

I remember when he said he was able to do this I immediately thought "no way" but the last time I had my car up on the lift I looked carefully around the area of the bottom of the IP and I came to the conclusion that it might be possible - but it sure wouldn't be easy.

When I resealed my the IP on my 91 2.5 turbo I removed the pump - once the pump is on the bench its a 15 minute job to change the seals.

How hard is it to remove the IP?

Are there any other issues I might be able to resolve with the IP out?

It's not too hard, I'd rate it a 6 or 7 on a 1-10 scale. You do need some specialized tools to properly time the IP to the engine but you can "get-by' without them. Read the procedure in the 603 engine manual carefully and don't forget the the bolt that secures the IP timer is left-hand thread. Also don't forget about the 13mm bolt at the extreme rear of the pump.

I'm not sure what you mean by your second question, If I was removing the pump I'd replace all the seals before I re-installed it - that might resolve future leaks. You might also want to consider replacing the seals on the fuel heater - they also will leak over time and its much easier to get at the fuel heater with the IP out of the way.

That's exactly what I meant by that.

This is a 602 engine, though.

Does the timing device you speak of look like this?
http://i13.ebayimg.com/01/i/001/23/df/b85d_1.JPG

That is a "Version" of the tool...
 

I believe it was gsxr that suggested the Official version with the RED plastic
handle was more finely machined in the Slot and fitted the IP shaft indent
better.

Does anybody have a link to the complete procedure for adjusting timing?

My timing chain is spot on, my IP has new delivery valve o-rings and pressure valve seals and my mpg is going down.

I know that it's really hot, my A/C is working it's tail off and one of my auxiliary fans has stopped working, but I expect better than 25 mpg in almost all highway driving.

I must also say that I drive in a very hilly and very windy part of the world but if some posters on here are telling the truth about their MPG(38.4?, 30/31 in mixed driving?) I am getting hosed.

Here is somemore pics of a timing pin. This one is made by (spelling?) Assenmacher tools.
The text is from a Mercedes special tool site.
http://i242.photobucket.com/albums/f...esel911/zq.jpg
Engines 601, 602.91 /93 /94 /96, 603.91 /93 /96 /97, 605.91, 606.91 /96, 617.95, 602.981

pdf on how to use the timing Blocking/Locking pin
http://www.ps2cho.net/downloads/MB%20CD/W124/w124CD1/Program/Engine/602_603/07.1-8410.pdf

Timing infor might be found at this site:
http://www.ps2cho.net/downloads/MB%20CD/W124/Main.html