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  #1  
Old 04-17-2014, 11:33 AM
louis4052's Avatar
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Rebuild those lift pumps! OM616 OM617

Hello folks!

I just wanted to post about the failed lift pump check valves on my wife's 1985 300D. Last tuesday I was on my way to meet my wife at work and drop off our 8 month old boy. The phone rang and she said she was stuck. You're stuck at work I asked? Nope. She was sitting in her stalled car on the side of a highway exit ramp, she though she had run out of fuel. I stopped and filled up a two gallon gas can, filled up her tank and tried to prime the fuel system with the hand pump. No dice, no flow, no pressure, nothing. Two hours later we had the car towed home.
The next day I swapped out both filters, pulled vacuum on the hard line with a might vac and got fuel from the tank but could not get the hand primer to move anything. Cranking didn't seem to move any fuel either.
I pulled the lift pump and could not get it to move any fuel on the bench. Rebuild time. I replaced the check valves and springs and the lift pump was working on the bench. Got it back in the car and she primed like a champ and fired up in a few seconds.
The old check valves had worn down by about .020".
The car had no symptoms of a week lift pump before it quit on the side of the road. Cost was $10 for parts and a few hours to diagnose and fix.
Go and rebuild your pumps now and don't get stuck by the side of the road!

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The Hills of Western Mass.
1985 300TD 327,777 sold to JB3
1985 300D 218,xxx
1987 190D 5 speed 338,xxx
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  #2  
Old 04-17-2014, 11:39 AM
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Can you share part numbers?

I have a spare pump I have already planned to rebuild as an experiment/learning experience and I don't think I ordered any check valves. I just have replacement springs and seal rings/washers.

Thanks!
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  #3  
Old 04-17-2014, 11:57 AM
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check valves # A 000 090 02 10 (check valves, springs and crush washers)
pump gasket # 001 074 22 80
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-Louis
The Hills of Western Mass.
1985 300TD 327,777 sold to JB3
1985 300D 218,xxx
1987 190D 5 speed 338,xxx
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  #4  
Old 04-17-2014, 12:53 PM
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218k on the pump that stopped working? Seems very low....all of our 617s have way more miles than that (as does my 601) and none have had any issues. Maybe the fuel is more abrasive in that area?? In fact my 300SD has 322k and still pumps fuel no problem. I have not touched the IP in 125k miles that I've owned the car.
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  #5  
Old 04-17-2014, 01:02 PM
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The car had 170k on it when we got it. It was plugging fuel filters like crazy and I replaced all the fuel lines in the engine bay. They were original and breaking down internally sending black crud everywhere. I've been meaning to drop and clean the tank for a while, I get a lot of rusty crud in the pre-filter which could explain some of the check valve wear. The pump innards were pretty spotless though.
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The Hills of Western Mass.
1985 300TD 327,777 sold to JB3
1985 300D 218,xxx
1987 190D 5 speed 338,xxx
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  #6  
Old 04-17-2014, 01:18 PM
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The Fuel Supply/Lift Pump Valve Kit for some reason does not come with the 0000900210
The 5mmØ x 1.50mmØ 'O' ring is located in a groove in this bore and prevents engine oil in the IP from being sucked into the fuel re-circulation circuit. In most cases this O-ring has either hardened and broken up or completely disappeared.

When I did mine I scrounged a 5mm O-ring locally from a BMW Motor Cycle Dealer.

The complete rebuild kit is I believe Bosch DGK-301 Fuel Supply/Lift Pump kit

There is some threads on the above stuff.
Attached Thumbnails
Rebuild those lift pumps! OM616 OM617-lift-pump-1-april-13.jpg  
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  #7  
Old 04-17-2014, 01:33 PM
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Quote:
Originally Posted by Diesel911 View Post
The Fuel Supply/Lift Pump Valve Kit for some reason does not come with the 0000900210
The 5mmØ x 1.50mmØ 'O' ring is located in a groove in this bore and prevents engine oil in the IP from being sucked into the fuel re-circulation circuit.
All of the DGK301 kits that I have installed (around a dozen) came with said o-ring. Two, in fact: one for diesel and one for gasoline.

That kit is applicable to a lot of heavy equipment, generators, etc., so it's commonly available, usually under $10.
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Old 04-17-2014, 01:37 PM
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Originally Posted by pawoSD View Post
218k on the pump that stopped working? Seems very low....all of our 617s have way more miles than that (as does my 601) and none have had any issues.
No issues that you know about, perhaps. You might be surprised at the results if you overhauled your fuel pumps.
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  #9  
Old 04-17-2014, 01:53 PM
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Here's one for the M pumps

http://www.peachparts.com/shopforum/diesel-discussion/294499-refreshing-fuel-pump-om617-european-spec-%96-non-turbo.html
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  #10  
Old 04-17-2014, 01:54 PM
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[QUOTE=tangofox007;3317572]All of the DGK301 kits that I have installed (around a dozen) came with said o-ring. Two, in fact: one for diesel and one for gasoline.

That kit is applicable to a lot of heavy equipment, generators, etc., so it's commonly available, usually under $10.[/QUOTE}

That was part of the point I was trying to make was was the Valve Kit does not come with the O-ring but the DGK301 kits does.
There is some company that selles generic DGK301 kits for something like $8.50.
There also is a DGK301H that has a new Hand Primer in the Kit.

Bosch Sells the 5mm O-ring in Viton. One of our Members posted that. From My Notes:
Bosch lists now 2 440 210 002 (MB 010 997 86 48) as replacement to the original black(perbunan?). And yes,the replacement is Viton.

Peilcan sells the Valve Kits that do not have the O-rings I am not sure if Pelican has the O0rings as a separate part of not. But, if Pelican supplied the O-ring it would be nearly a 100% rebuild kit. The only item missing would be the Copper Crush Washer for the 30 or 32mm Plug (can't remember the Wrench size on that).
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  #11  
Old 04-17-2014, 09:20 PM
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A bad fuel pressure relief valve can also cause these same symptoms.
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  #12  
Old 04-18-2014, 09:30 AM
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Think about it...
I had to rebuild my lift pump, but with some of the responses here, that many owners have not had to rebuild the lift pump is remarkable and a testiment to the quality that went into these cars!
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  #13  
Old 04-18-2014, 09:49 AM
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Originally Posted by junker68 View Post
Think about it...
I had to rebuild my lift pump, but with some of the responses here, that many owners have not had to rebuild the lift pump is remarkable and a testiment to the quality that went into these cars!
If only that same level of quality had gone into the ACC, tachometer amp, seat springs and instrument lighting!!!
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Old 04-18-2014, 08:12 PM
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Originally Posted by tangofox007 View Post
If only that same level of quality had gone into the ACC, tachometer amp, seat springs and instrument lighting!!!
It has, but age didn't do these parts any good. People for get these cars are over 30 years old....things weren't tested to see if they would last 30 years....the seat springs break do to age, rotted padding, rust. ACC has stuff that doesn't age well rubber, electronics, a capacitors life span is no more then 15 years. Same goes for the tach, instrument lighting works wonders if you clean grounds, rheostat, etc....people need to learn age is the greatest defeat on anything no matter how well it was designed.
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Old 04-18-2014, 10:04 PM
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Originally Posted by cooljjay View Post
People for get these cars are over 30 years old...
People forget that some of us have had our cars for 30 years. Or close to it. There are some problems that have a lot more to do with poor design than age.

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