So after a full engine rebuilt only one issue remains. The vacuum pump. Somewhere along the line the previous owner had put in an electric vacuum pump because the mechanical one had disintegrated. After sourcing a used vacuum pump and cleaning it up the remaining thing to do is install it. However to avoid it from somehow disintegrating I need to install it properly. The vacuum pump is the diaphragm one with two ports from a 1979 240d. Is there a position in which the engine timing device has to be before I install it? Do the raised ridges on the timing device somehow correspond with the swing arm in the vacuum pump?

the raised edges if the ones you are talking about sort of look like a roller coaster drive the swing arm. The is no specail alignment. Just bolt it on. I would check the bearings in the swing arm that ride on the "roller coaster" Don't want to waste a new engine on bad bearings that may fall into the timing chain.

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1977 240D turbo

So I basically position the two ports upward to where i can connect the hose to the air cleaner and central vacuum and bolt on.

I definitely should check the bearings. That's what caused the need for an engine rebuilt in the first place.

I wouldn't trust a used pump long-term. The ball-cages on the original bearings are plastic and may be ready to disintegrate after so many years. There may be a new lever & bearing kit availible . At least that's what I wound up installing in my '82 240D's pump. The kit was quite pricey though - about $260!

Happy Motoring, Mark

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DrDKW

For my model the pump cost $400 which I don't feel like spending. As for the rebuilt kit I have searched all over with no result. So basically this is my only option.

If your bearing is a 6001 they are very cheeep on our favorite auction site.

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1985 300D 198K sold
1982 300D 202K
1989 300E 125K
1992 940T

"If you dont have time to do it safely, you dont have time to do it"

"The democracy will cease to exist when you take away from those who are willing to work and give to those who would not."

WOW!! just checked on Fastlane, and the early style pump is $517.74.

Repair kit is $255.67.

Later style pump like on the OM617.95 is $394.60, but the repair kit is not available.

wouldn`t the later style pump fit the OM616 engines???

Call phill if something is not avail on the site. he has connections.

Charlie

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there were three HP ratings on the OM616...

1) Not much power
2) Even less power
3) Not nearly enough power!! 240D w/auto

Anyone that thinks a 240D is slow drives too fast.

80 240D Naturally Exasperated, 4-Spd 388k DD 150mph spedo 3:58 Diff

We are advised to NOT judge ALL Muslims by the actions of a few lunatics, but we are encouraged to judge ALL gun owners by the actions of a few lunatics. Funny how that works

Since people have thie own idea of what they consider a rebuilt Engine:
New Vacuum Pump Ruined due to too much Timer/Intermediate Shaft End Play (the title from my notes).
http://www.peachparts.com/shopforum/showthread.php?t=258062&highlight=vacuum

What year is the the Engine; does it have the port in the Intake Manifold to connect the Vacuum Pump to?

I would like to see pics of the Electric Vacuum Pump and what type of Vacuum Shutoff Valve was used.

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84 300D, 82 Volvo 244Gl Diesel

The engine is a 1979 om616 with two ports, one from the intake.

I don't have pictures of the electric vacuum pump but it is a stainless steel brakes model 28146. I have started the engine and ran it with the electric pump for a while with the mechanical pump just capped off. The problem was that the electrical one was running constantly and would not shut off. I figured it was the solenoid that should shut the pump off when there is enough vacuum. So two weeks later and $70 spend my solenoid finally arrived. After installing it I still had the same problem and after many hours of problem solving I finally gave up and decided to go with the mechanical pump.

To install the vacuum pump rotate the engine by hand so the valleys of the roller coaster on the timing device are virtual, that way your not working against the spring.

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1985 Euro 240D 5 spd 140K
1979 240D 5 spd, 40K on engine rebuild
1994 Dodge/Cummins, 5 spd, 121K
1964 Allice Chalmers D15 tractor
2014 Kubota L3800 tractor
1964 VW bug

"Lifes too short to drive a boring car"

I tried the below with no Vacuum Shutoff Switch or a Check Valve in the system. Since that time I have bought a Check Valve but will stick with the Mechanical Pump until I have a Vaccum Shutoff Switch.
http://www.peachparts.com/shopforum/diesel-discussion/296397-electric-vacuum-brake-booster-pump-tested.html

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84 300D, 82 Volvo 244Gl Diesel

There are two repair kits for the two types of vacuum pump:

Old style membrane pump:
repair kit 1: membrane, valves and gaskets
repair kit 2: rocker arm

New style piston pump:
repair kit 1: rubber piston ring, rubber piston band, valves, gasket
repair kit 2: rocker arm

The rocker arm repair kit (the most expensive) can be bypassed by putting in new bearings in the old rocker arm. Loose bearings are much cheaper. The repair kit 1 is not cheap either. New pumps are very expensive.

nikkondy,here is an installation instruction from the OEM:

http://www.ms-motor-service.com/ximages/pg_si_0025_en_web.pdf

Thank you. This is exactly what I was looking for. I appreciate your help.