Update
today i received a replacement Diaphragm For Pneumatic Govenor
similar to this
https://www.ebay.com/itm/221872852867

Question. do I have to remove the IP to replace this or can I do it with the IP still intact

You can do it with the ip in place. It has been 15 years since I have done it, but I did not remove the ip.

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1985 300 TD 448K
1984 300 TD 278K

1983 240D euro 240k
1994 f-250 idi turbo 330K
1986 f-350 IDI
1987 F-350 IDI

1985 JD 1050 4wd
1965 IH 3660

thanks , dont have any tips or photos to help me with this ?

all i have is this

https://www.youtube.com/watch?v=6pAG5CWag84

I remember it being difficult to attach it on the inside of the diaphragm, but I used forceps and maybe a cosmetic mirror to help me see what I was doing!??.
Sorry it was a long time ago.
My son's 115 is smoking too much for his liking now. He is going to check his pneumatic governor system soon. If we get into his I will have a fresher idea of how to do it.

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1985 300 TD 448K
1984 300 TD 278K

1983 240D euro 240k
1994 f-250 idi turbo 330K
1986 f-350 IDI
1987 F-350 IDI

1985 JD 1050 4wd
1965 IH 3660

Thanks , ill give it a try..

Im close to my wits end with this motor.

body, transmission, interior and suspension are good.

But something is a miss with the 616.. Maybe its the pump or compression is low.

Unfortunately in my area , not many specialists want to do engine rebuilds on old diesels

Finally
managed to change the IP governor diaphragm.
was a very tedious exercise

however in doing so , ive made things worse

i have far less acceleration now when taking off from traffic lights
have to hold the pedal to the floor before it will kick down a gear.

once up to speed its ok

is this a throttle linkage issue ?

Did it kick down before without holding the pedal to the floor? I've never known a 240D auto that I didn't have to floor it from standstill so as to engage the kickdown switch under the accellerator. Once you get going does it drive normally or are you underpowered all the time?

- Peter.

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2021 Chevrolet Spark
Formerly...
2000 GMC Sonoma
1981 240D 4spd stick. 347000 miles. Deceased Feb 14 2021
2002 Kia Rio. Worst crap on four wheels
1981 240D 4spd stick. 389000 miles.
1984 123 200
1979 116 280S
1972 Cadillac Sedan DeVille
1971 108 280S

A throttle linkage issue is high on the list. When the pedal is fully depressed is the pump at full supply and does the blade at the air intake fully open. Check the air intake for debris/restrictions e.g., a rag.

Good luck!!!

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"Rudeness is a weak man's imitation of strength" - Eric Hoffer

It used to kick down a lot easier before without holding the pedal to the floor.

Once i get up normally it seems as before.

The other improvement is it seems quieter and less smokey

By kickdown do you mean downshift through throttle pressure or a forced electrical downshift? If it isn't winding the gears as long as it used to nor downshifting unless it is completely floored then I think it is linkage related an or the bowden cable adjustment. re-examine all of the work done before changing or adjusting anything else. Without seeing it before and after, my guess is the linkage fulcrum point on the top of the valve cover is pivoting in the wrong direction.

Good luck!!!

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"Rudeness is a weak man's imitation of strength" - Eric Hoffer

Downshift through throttle pressure... once it gets up to speed it seems fine .

I had to take off the throttle coupling attached to the IP to get access to the diapghragm

This is to be expected. You went from too much fuel being delivered to something closer to spec.

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- Greg -
1973 220D, The Prodigal Benz
1974 240D

Darn
cant see what ive done to make the throttle worse..
all i took off was the end of the IP ( which has the throttle linkage attached to it )
didnt adjust it at all