so my dumb self goes to tighten the deliveryvalve...and it snaps off inside the injector pump...what do i do now?????

Umm, what model engine/car?

Kurt

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- '79 240D - engine swap complete! Engine broken in! 28-31 mpg! Lovin' the ride!
- '86 190D (W201-126) - 2.5 NA engine, 5 speed, cloth interior, manual climate controls, 33-34 mpg (sold to forum member).

See the Ezieouts in the pic.
You only need to buy one but you want one that will grip only about 1/2 way down inside of the Delivery Valve Holder and there are several types of the short one pictured however besure they are short enough (you might need to grind one shorter.)

You will need to remove the Delivery Valve Spring, the Delivery Valve (the central valve) and the outer Delivery Valve Body. (Note which end faces the Delivery Valve because the Central Delivery Valve only seats on one side; somtimes the outer body is marked with a band to show which side goes down or up.)

You do not want the Ezieout to go all the way to the bottom and touch the Element Face (Plunger/Barrel face) and you do not have to pound it in as firmly as you would do on a bolt.



Heat the Fuel Injection Pump Housing with a Hair Dryer/Blower.

The cracked off piece should not be in there too hard; not like a Bolt.

Attached Thumbnails

 

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84 300D, 82 Volvo 244Gl Diesel

Don't forget to find the correct torque and use a good quality torque wrench. This is no place for a Chainese click type foot pound torque wrench.

If you have to get a cheapie torque wrench for this job get a Beam type one.

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84 300D, 82 Volvo 244Gl Diesel

ok thanks for the reply...its a 99 e300 td....where can i get this easy out set?

Please don't take this the wrong way, but you have two threads running pertaining to the same problem, and after reading your posts, it appears you don't understand the seriousness of the repair you are trying to make. If you do not make the repair properly, and you damage the injector pump, you are looking at a major expenditure of money and time to the tune of possibly $2000 to have it fixed. If I were you, before doing any more work, I would look at the link below and see what your are facing. This is not just a matter of picking up a wrench and doing it the way you think it should be done, it must be done in a certain way to certain specifications. Good luck




http://www.peachparts.com/shopforum/showthread.php?t=211801&highlight=delivery+valve

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96 E300d

I would pull the pump and drop it off at a Bosch service center and let them deal with it at this point.

Its probably going to need to be flow tested before it works right anyway.

Do you have pics?

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Terry Allison
N. Calif. & Boca Chica, Panama

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

Delivery Valve holder with the Fuel adjustment for his Elements us under the Flat Sheet metal Cover and on the Fuel Rack itself.

As long as the outer "Barrel" of his Element is not pulled up and out of the pin and slot that lines it up he will have no issues with and change in his fuel amount.

However, I think he is better off sending it to a Bosch Shop also because if his apparent level of skill that has been shown so far.

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84 300D, 82 Volvo 244Gl Diesel

my level of skilll will stay the same if i take it somewhere and have them do it. so i would appreciate help on the issue at hand

You are in uncharted territory claiming to have broken off a DV Holder inside the IP. Can't imagine how much torque it took to do that or what happened internally. Spec torque is 35NM or 26 ft lbs. Is not much, just enough to seat the holder on the crush washer and to compress the oring.

If your pocket book can handle the hit of a used/rebuilt IP (~$1500-2500) then have at. Again, you are in uncharted territory so not being able to see pics and understand exactly whats happened is going to limit the amount of useful input you receive. You obviously cant drill because you cant risk contaminants and you can't beat on it or heat it with a torch cause you might warp something or melt other seals you can't get to. Probably leaves some sort of easy-out. Might want to talk to a local guy who extracts broken head bolts for ideas...?

If your pocket book can't take the hit of a used or rebuilt IP, the Bocsh tech and a flow bench will prob run $1k, if it turns out in fact to be a recoverable mistake.
******************
Ref the attached detail: http://homepage.ntlworld.com/tom.jeffs4/car%20stuff/merc%20tech/diesel%20delivery%20reseal-1-1.pdf

You snapped #7 off inside the IP, right?
Did you pull #7G up out of the hole before you did that?

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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 was not trying to be rude about the Skill Level comment.

I had my share of heat breaking and expensive adventures trying to self teach myself stuff (on he first Car I owned I tightened my Head with no Torque wrench because I did not have the money for one. It ran a few years with no problems but when it came time for the rebuild the Head was cracked.
(Later my Father talked me into going to Trade School where I took Diesel Mechanics.)
I do not see removing the cracked off Delivery Valve Holder as a major issue if you are careful.

Note: It is not un-known for the Deliver Valve Holders to crack all on their own from vibration or ???.

Back to the skill level issue. What people are saying is that due to the cost of the Fuel Injection Pump the self teaching issue could be expensive.

Skill levels:
We have members of our forum who do very little to their cars themselves because they doubt there ability.
We have people who have been mechanizing on all kinds of stuff for a long time.
We have a small group of members who were or still are professional Mechanics.
But, once and a while someone comes a long who is a little too bold in thinking they can do things just because the think they can. This type of person is often unable or unwilling to follow reasonable instructions. (I am like this once and a while myself.)
The problem with giving instructions on the Fuel Injection Pump is few have gone very far into them; and, if you go to far you get into areas of the Fuel Injection Pump that can only be adjusted back to spec on a Calibration Stand.

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84 300D, 82 Volvo 244Gl Diesel

thanks so much for your help!! i was able to extract the broken delivery valve and replace everything! fired right up and i took it on a 2000 mile trip this weekend with no prooblem! im glad i was able to do this with yalls help

Perfect!

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84 300D, 82 Volvo 244Gl Diesel

Outstanding!!!

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96 E300d

I forgot to as what method you decided on to extract the broken off Delivery Valve Holder?
I am sure others would like to know incase it happens to them.

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84 300D, 82 Volvo 244Gl Diesel