I recently put this engine back in and I'm working on getting it started.

While bleeding the injector lines I have found that the IP is not pushing any fuel out of the #4 port.

I disconnected the line at the IP and verified that there is no fuel coming out of the IP for the #4 line.

I know just about nothing about the internal workings of the IP so I'm a bit concerned. The IP did sit idle for about 4 years but had oil in it during that time.

Any ideas what could be the cause?

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1987 300SDL 167k
1992 Volvo 740 140k
1990 Volvo 740 250k
1989 Volvo 240 269k

Anyone want to trade an old Volvo for an '87 300sdl?

yup, the pump is seized internally because you didn't store it immersed in a bucket of ATF.

remove the pump and take it to a specialist.

DO NOT try anything else, because it will involve dislodging rust or dirt, and instead of one pump element gone it'll be two or three.

I figured this wouldn't be easy.

When you say specialist are we talking MB specialist or a diesel mechanic?

There are diesel mechanics around but nothing for MB.

__________________
1987 300SDL 167k
1992 Volvo 740 140k
1990 Volvo 740 250k
1989 Volvo 240 269k

Anyone want to trade an old Volvo for an '87 300sdl?

Diesel fuel injection shop, ask your local diesel truck shop where to go.

If you're lucky it will just be a strip and clean and calibrate, mebbe 100-150 bucks.

100-150 bucks? Don't know what that translates to in US dollars but it isn't going to happen at any US BOSCH operation for less than probably $300 minimum!

Here is an old thread that concerns a similar issue, there isn't much to read but it might be worth it to try and contact the OP to get a better understanding of what weht on with his IP and how he figured out to do what he did to fix it, good luck!

http://www.peachparts.com/shopforum/showthread.php?t=33570

Doesn't have to be bosch, any injection shop can do it.

Can't a buggered, dirty, or hung-open DV cause the barrel to not prime/pump?

__________________

Gone to the dark side

- Jeff

thats exactly what I was thinking.

for $30 from a Bosch shop, you can buy a new delivery valve and drop it in there.

pretty easy if you have the right socket.

yup, it can, now are you going to assume that it is just one flake of dirt in the entire pump, or are you going to get an injector shop to clean the pump and give it a good bill of health, and then basically not worry about it (or removing it) again for the next ten years?

Thanks for all the help guys.

I must admit, I'm a bit confused. Is the conclusion that this problem is due to the IP being stored without being dunked in oil or is it that there is dirt in the IP?

I did keep the IP covered while stored and was very careful not to allow any dirt into the IP.

If the IP should have been stored in ATF would dunking it in ATF now possibly free up the stuck parts?

__________________
1987 300SDL 167k
1992 Volvo 740 140k
1990 Volvo 740 250k
1989 Volvo 240 269k

Anyone want to trade an old Volvo for an '87 300sdl?

I'll be waiting to hear someone chime in with any injection shop anywhere in the US that will open up, clean and calibrate one of these BOSCH MW IP's for anything less than $300!

Looks like your somewhere in the UK and 100-150 bucks may be the going rate there but I very much doubt it anywhere on this side of the pond! Perhaps you actually know of and have done business with some shop that does that work at that rate over here, and if so I'm sure that more than just the OP would love to hear where that is. In fact I've got a couple 603.96 and .97 IPs I'd pay to have cleaned and calibrated right now!

it doesn't have to be dirt.

If a surface corrosion formed inside the delivery valve carriers, then a delivery valve could be stuck in its holder.

You can easily find out if this is the case by borrowing the splined socket tool from someone.

You pull the carrier off and the delivery valve is right there under a spring just waiting to be replaced.

There is one poster who has come to that conclusion, despite the thousands of IP's that are not stored in that manner which have been stored for long times and worked once they where installed. Its' simply a jumped to causation when there has not yet been a defect determined responsible for the malfunction. He might be right but it wouldn't be based on any facts!

The reality is you don't know why your pump is malfinctioning, as others have stated it could be a delivery valve issue. I provided the link I did because in that case it was a similar non-fueling of a cylinder issue which Henry discovered was an issue internal to the control mechanism of the IP. As it turned out one that he was able to remedy pretty easily!

You best course of action if you don't want to spend alot of money up front is to remove the delivery valve and inspect that for any obvious defect, could be dirt/rust in there, broken spring, who knows. If nothing is obvious and it still doesn't deliver fuel after playing with it, I would swap that DV with one from an adjacent element that you know is functioning. If that then you get fuel from the formerly fuel-less element the DV needs to be replaced, if there is no change in the malfunctioning condition, it would seem to me that the issue resides deeper internal to the IP.

If that is the case I would try to contact Henry and perhaps he could better explain how he discovered the cause of the problem that he found on his pump and exactly what he did to get it to work correctly. Sounds like something was disconnected inside his pump and he was able to reconnect those parts and restore the fuel flow to the fuel-less element. You'd likely need the IP off the engine, thea IP lock tool to reinstall it, and at least one gasket where you take the side plate off the IP to get a look inside. Good luck, I'll be watching this thread to see what is discovered and hopefully fixed.

P. S. 615/616/617 engine IP procedures remark that gasoline run through the IP is used to remove "varnish" from the internals. I have done this on a 616 engine that was sitting for about 6 years in the hope of resolving an issue that seened like it could be IP fuel related, it didn't fix that particular problem which turned out the be piston ring related. Essentially with the IP in place, a couple hoses the feed with an inline filter into a jug of gasoline, the injection lines off the pump, crank it over until you observe fuel pumping out of each element. I let it sit for a couple hours and did that again. Get rid of the gasoline jug, substitue a jug of diesl and pump that through by turning over the engine to flush out the gas. Make sure you're getting even pumping of fuel out of the elements and put the lines back on.

I hadn't heard of IP's being stored in ATF but then again I've never stored one before.

I'll have to get a splined socket and swap the delivery valves and see what happens.

Maybe the gasoline flush as well.

I'll keep my fingers crossed, I've had about enough dumping money into this project for now.

I read another thread where someone sprayed WD-40 into a delivery valve. So long as it is flushed out with diesel does that sound like a bad idea?

__________________
1987 300SDL 167k
1992 Volvo 740 140k
1990 Volvo 740 250k
1989 Volvo 240 269k

Anyone want to trade an old Volvo for an '87 300sdl?