IP stop lever shaft disappeared into the IP - PeachParts Mercedes-Benz Forum

abrankhalid · #1 06-19-2013, 07:52 PM

Hello !
I am in a major pickle. Today was trying to replace the O-ring around the stop lever on the injection pump . Everything went well until I had to put the clip and shaft back on. In trying to get the c-clip back on the shaft that goes in to the hollow 17-mm nut on the injection pump, i pressed on the shaft and it slipped in to the nut . When i tried to pry it out, it slid in more.
I opened up the 17mm nut but there was no shaft inside it. I tried prying in the opening with a pick but nothing. What should I do ? It seems highly abnormal that of so many people who have done this tiny repair , no one came across the problem. Is it a possibility that something was already broken inside the I.P ?
Any ideas on how to retrieve the shaft and connect the stop lever to it ?

Thanks in advance for all the help !

pawoSD · #2 06-19-2013, 10:52 PM

a small powerful magnet stick might fit in the hole and grab/slide it back out....

Diesel911 · #3 06-20-2013, 12:45 AM

Don't rotate the Fuel Injection Pump; the Governor Weights will swing and at the least wedge the part in; at the worst if you crank the Engine it will crack the Governor Housing.

This is the most original thread I have read in 5 years; no one has had the problem before.

I have never seen Your Fuel Injection Pump; but I would be looking for something like the Vacuum Shutoff (if it has one) to remove so that I could get inside and see what is going on.

Even if you manage to snare it with a Magnet you need to figure out how the Lever is positioned inside of the Housing. Otherwise when you start it the Engine might run away.

C.Doner · #4 06-20-2013, 01:17 AM

Hopefully the pump doesn't have to come off.

Stretch · #5 06-20-2013, 03:27 AM

Quote:

Originally Posted by Diesel911

...
This is the most original thread I have read in 5 years; no one has had the problem before.

...

X2

There are some pictures in this thread that might help

http://www.peachparts.com/shopforum/diesel-discussion/306090-papas-got-brand-new-om617-ip-play.html

abrankhalid · #6 06-20-2013, 06:27 AM

Quote:

Originally Posted by pawoSD

a small powerful magnet stick might fit in the hole and grab/slide it back out....

As far as i could feel around with the pick, there was nothing in that hole at all. it seems like the shaft fell in to the interior of the I.P . I am planning to get hold of some magnets and then try to get it out through some other orifice.

abrankhalid · #7 06-20-2013, 06:29 AM

Quote:

Originally Posted by Stretch

X2

There are some pictures in this thread that might help

Thanks Stretch. I have looked arond some threads to understand how the shaft is attached inside and also what i should expect to find inside the I.P. That thread will also help. B.T.W , I completed the dash recovery. I am posting high quality pictures today to that thread in Interior and detailing. It turned out pretty well for a first timer.

abrankhalid · #8 06-20-2013, 06:36 AM

Diesel911 : I guess having a unique problem has some fun attached to it ! I made sure not to move the engine or the I.P at all after the shaft disappeared. I am going to open up the Shut Off Valve and see if i can make sense of where the shaft may have fallen in.
My main concern after finding the piece of metal is how to attach it back. From what i understand, there is a spring that keeps the shaft in position. If the shaft fell off, would the spring be in there too ? I am hoping that some one who has seen the innards to chime in and help me out. There was a post by whunter about a rebuild video of an IP but that hasn't come through yet. I.P is not something I relish tackling as there isn't much a layman like me can accomplish by opening it up.

Stretch · #9 06-20-2013, 08:26 AM

Quote:

Originally Posted by abrankhalid

...I.P is not something I relish tackling as there isn't much a layman like me can accomplish by opening it up.

From my limited understanding you should be OK so long as you don't mess with the pump side of the IP at all and you limit the messing about with the governor side =>

meaning =>

If you mess with the pump settings you need a test bench to set it right again

Don't mess with the connection between the governor and the rack (I understand that the stop lever is close to this but is still separate but I'm not 100% sure as I haven't really gotten into how these things work just yet)

Have you had a look at the description of operation in the FSM? (Chapter 07-010) It might give you a bit more confidence. There is actually slightly more information in the non turbo version of chapter 07-010...

...it isn't immediately apparent where the stop lever actually is in the schematics though. I think it acts on the accelerator linkage...

...does anyone know for sure?

The Gears · #10 06-20-2013, 09:20 PM

The VCV can be easily undone and rotated, do not try to remove, just rotate 90 deg and shine a flashlight down inside the IP. You may be able to see what you are looking for.

Diesel911 · #11 06-20-2013, 10:20 PM

1987 190D 2.5 Non-Turbo have an MW Fuel Injection Pump or an M type Fuel Injection Pump.
I am guessing He has a M type. To ID it look at the Delivery Valve holders on the Fuel Injection Pump. It you need to use the special splined Socket to remove them it is an M type Fuel Injection Pump and I think it has a different Governor on it.

Diesel911 · #12 06-20-2013, 10:28 PM

Quote:

Originally Posted by abrankhalid

Diesel911 : I guess having a unique problem has some fun attached to it ! I made sure not to move the engine or the I.P at all after the shaft disappeared. I am going to open up the Shut Off Valve and see if i can make sense of where the shaft may have fallen in.
My main concern after finding the piece of metal is how to attach it back. From what i understand, there is a spring that keeps the shaft in position. If the shaft fell off, would the spring be in there too ? I am hoping that some one who has seen the innards to chime in and help me out. There was a post by whunter about a rebuild video of an IP but that hasn't come through yet. I.P is not something I relish tackling as there isn't much a layman like me can accomplish by opening it up.

Post some pics of the Fuel Injection Pump.

Not as many people own the 190Ds. I am not sure how similar the Governor is on them to the later model Fuel Injection Pumps.

I have not even seen the insides of My own MW Fuel Injection Pump Governor.

I am trying to find a Pic of an 190D on eBay to see if that is what you have.

If your Fuel Injection Pump looks like the one below the Vacuum Shutoff is where the Green X is and the Shutoff Lever is where the Red Arrow is.
If that is true removing the Vacuum Shutoff looks like the only easy way to get in there and see.

300D-91 · #13 06-20-2013, 11:11 PM

Check this thread

http://www.peachparts.com/shopforum/diesel-discussion/328050-urgent-need-help-broke-fuel-shut-off.html

Stretch · #14 06-21-2013, 02:47 AM

^^^ looks like the solution to me - well done!

300D-91 · #15 06-21-2013, 05:51 AM

Good luck and I hope it helps.