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IP plungers orientation
Fine people,
In my 1991 W124 300D I had aleak at two of the delievery valves While changing the delievery valves O rings and washers... The crush washers fell inside and I had to use a screw driver to pick them up. I have messed up the original orientation of the plungers and now I can not get the engine to run like before or even idle smoothly. I tried all the guess work but still could not get it right. A diesel place wanted to rebuild the whole IP for $2600 The plungers have two holes... one is "small" lowerer than the other "larg" While the body of the pump has got two holes. I have done lots of search but could not fine how to set the plungers back to their correct hole orientation. Would any one able to help with setting the plungers back to the correct orientation please? Highly appreciated Regards, Fitian <><
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* 1991 W124 300D 480.000 kms Running on WVO * 1991 W124 300D 230.000 kms Running on Diesel * 1997 W210 E300 280.000 kms Running on Diesel |
#2
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Not MBZ nor A/C trained professional but a die-hard DIY and green engineer. Use the info at your own peril. Picked up 2 Infractions because of disagreements. NOW reversed. W124 Keyless remote, PM for details. http://www.peachparts.com/shopforum/mercedes-used-parts-sale-wanted/334620-fs-w124-chasis-keyless-remote-%2450-shipped.html 1 X 2006 CDI 1 x 87 300SDL 1 x 87 300D 1 x 87 300TDT wagon 1 x 83 300D 1 x 84 190D ( 5 sp ) - All R134 converted + keyless entry. |
#3
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You DO need to have it calibrated (not a DIY job) as moving internal parts and not getting them back to the exact same positions will easily cause what you're describing.
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1987 300D (230,000 mi on a #14 head-watching the temp gauge and keeping the ghost in the machine) Raleigh NC - Home of deep fried sushi! |
#4
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I don't know what prices are running, but my local shop gave me a price of $450 to do DV seals, re-seal the outside of the pump, turn up the full-load and high-idle, and calibrate the pump. As Sean says, $2600 seems high for only part of this service.
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Gone to the dark side - Jeff |
#5
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#23 is the Delivery Valve Holder (sometimes called a Pipe in the FSM) #27 The Delivery Valve Spring #44 Is the Delivery Valve. It has 2 pieces and the 2 pieces are mated to each other meaning that parts should not be mixed. The Central Valve in the Delivery Valve is only fitted to one side. This means that the Outer Ring portion of the Delivery Valve is only supposed to fit one way. #47 is the Plunger and Barrel Assembly (called an Element in the FSM). The part on the bottom (in the center) that goes up and down is the Plunger. The outer tube is the Barrel. The Barrel has a slot (in the upper middle) in it that lines up with a Pin in the Fuel Injection Pump Housing. If for some reason the Barrel us pulled up and rotated the Pin is not going to fit into the slot. If it is torqued back in place like that there is a chance of damaging the Fuel Injection Pump Housing. It is even possible to bend the Pin inside of the Fuel Injection Pump Housing. One of the ways to tell if the above has happened is when installed the Delivery Valve Holder will stick up higher than the properly installed ones. #48 connects the Plunger to the Rack. If the Plunger is Pulled out completely and you cannot remember how it was lined up; you will have to use trial and error because the Plunger can go in 2 ways.
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84 300D, 82 Volvo 244Gl Diesel |
#6
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Answer
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The price they gave is IMO very high. http://www.youtube.com/watch?v=POlOSBVIXe8 http://www.youtube.com/watch?v=Qty6ZK8o6U8 http://carlton.carmechanic.net.au/diesel-engine-tuning/1962 http://www.moorediesel.com/diesel_fuel_injection.html http://www.sydneydieselcentre.com.au/service.html http://www.autosource.com.au/diesel-cars.php http://www.dieselject.com.au/ http://www.griffithdiesel.com.au/ http://lismorediesel.com.au/ http://www.hastingscbd.com.au/dieselinjection.html Deutz Australia Pty Ltd Engines-Diesel &/or Equipment & Parts - Springwood, QLD Dennis Court Unit 12/ 8 Dennis Rd, Springwood QLD 4127, Australia (07) 3290 0988 Diesel Technology (Springwood) Pty Ltd Engines-Diesel &/or Equipment & Parts - Springwood, QLD 17 Westerway St, Springwood QLD 4127, Australia (07) 3208 7124 .
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ASE Master Mechanic asemastermechanic@juno.com Prototype R&D/testing: Thermal & Aerodynamic System Engineering (TASE) Senior vehicle instrumentation technician. Noise Vibration and Harshness (NVH). Dynamometer. Heat exchanger durability. HV-A/C Climate Control. Vehicle build. Fleet Durability Technical Quality Auditor. Automotive Technical Writer 1985 300SD 1983 300D 1984 190D 2003 Volvo V70 2002 Honda Civic https://www.boldegoist.com/ |
#7
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That means they really don't want to rebuild your IP.
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'98 E300 turbodiesel |
#8
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Note: MB300D81 Location: Australia
It dose not matter what the price in the US is.
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84 300D, 82 Volvo 244Gl Diesel |
#9
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Look at this link. http://www.peachparts.com/Wikka/OM606DeliveryValveSeals it's pretty much the same as this: http://www.peachparts.com/Wikka/OM602InjPumpFuelLeak
If you put it with the numbers up. It's correct. Air in the system/lines takes a bit to work out. I might be totally wrong. But K.I.S.S. applies here. Unless the pump was wonkered up to begin with.
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92 300D 2.5L OM602 OBK #59 |
#10
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Hmmm
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Customers can ship them here for calibration or rebuild. |
#11
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On the intitial rebuild would there be a duty on it?
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84 300D, 82 Volvo 244Gl Diesel |
#12
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heh not sure what shipping to AU would be, but I've got a parts car 93 turbo 2.5 if that is the same motor in yours... I could ship it to CSEAN and have him do a set of DV seals and gaskets for you, and get it shipped up easier than dealing with a recal...
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John HAUL AWAY, OR CRUSHED CARS!!! HELP ME keep the cars out of the crusher! A/C Thread "as I ride with my a/c on... I have fond memories of sweaty oily saturdays and spewing R12 into the air. THANKS for all you do! My drivers: 1987 190D 2.5Turbo 1987 190D 2.5Turbo 1987 190D 2.5-5SPEED!!! 1987 300TD 1987 300TD 1994GMC 2500 6.5Turbo truck... I had to put the ladder somewhere! |
#13
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Thanks to all of you for your fast and kind replies.
I tries with numbers up ... did not get rid of the misfiring and still idle rough. The wholes on either side of the plungers were set both ways and yet still getting the same result. At one stage, I placed the plungers with the larg holes all lined up facing towards the front of the car and the engine started right up however the rpms went to the roof. and the shut off arm could not stop the engine. I had to pull the fuel hose and let it use all the fuel to stop "bad experience" I finally rang a diesel place and booked it in for resetting/calibration etc. cost is unknown but it starts from $2600 I will report back when it is done. Regards
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* 1991 W124 300D 480.000 kms Running on WVO * 1991 W124 300D 230.000 kms Running on Diesel * 1997 W210 E300 280.000 kms Running on Diesel |
#14
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Fine people,
I just got the car back from the diesel center. The car is drives well however, I noticed... it is reving somehow higher than before. Accelerator cable is not tight. RPMs is sitting between 5000 and 10000 RPMs while idle... What is the correct idle rpms? The knock is louder and sharper than before and does not go away. The car is running on pure diesel. I took the car back to the diesel center and they reckon the idle can be lowered down but I am not sure what is the correct rpms. Can someone advise on that please? Regards
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* 1991 W124 300D 480.000 kms Running on WVO * 1991 W124 300D 230.000 kms Running on Diesel * 1997 W210 E300 280.000 kms Running on Diesel |
#15
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1 Australian dollar = 1.0122 US dollars
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http://superturbodiesel.com/images/sig.04.10.jpg 1995 E420 Schwarz 1995 E300 Weiss #1987 300D Sturmmachine #1991 300D Nearly Perfect #1994 E320 Cabriolet #1995 E320 Touring #1985 300D Sedan OBK #42 |
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