Those om617 motors that are in the 300d's are tractor motors. As with any diesel, you can get more out of it, but the om60x series are much different. The four cyl is a om601. Pretty cool series since they have hydraulic valves, doing away with adjustments. I found a lot of extra hidden power by deleting the A/C, engine driven fan, EGR crap, modifiying the intake and exhaust and doing a TON of weight reduction on the car. The worst part about these engines is the way they nest the injection pump under the intake and the block access to the back of the pump with the oil filter flange. Not very mod friendly.
I don't want to get too sidetracked though. As stated, I got my injection pump apart. I understand that it you plan on doing a full rebuild, there is much more to it than just replacing seals. I wanted to take it all apart just so that I can get a better understanding of it and I had a feeling it would need a good cleaning. Boy was I right! I tried to take some pictures to give an idea on how it comes apart. I gained guidance from veeman's walkthrough on how to re-assemble it.
I already had the governor spring assembly out of it from a previous day so I don't have pictures of that. I am sure that most n/a people already know how to do that anyways
Then, onward to taking out the delivery valves and the head. As soon as you start taking the head off, you hear parts moving around and your heart stops for a second haha. It's okay. Once you look at all the exposed parts and the order you take them out, it starts to make sense.
That little piston shim falls out first and then the cam rollers can tumble out if you don't have the shaft pointing straight down. Not a big deal if you are taking a pump all the way apart but be extra careful if you are just trying to replace the seal for the head!!!
Taking out the centrifugal governor is fairy easy...just don't be a fool like me! I took the locknut completely off before backing out the shaft with a hex socket. I hope I can get it adjusted just right when I reinstall it but it would be wise to leave the locknut on to help keep track of where the shaft was before removal. Keep me in your prayers when I put this back in lol
After that, I took off the cold start lever and the cover on the opposite side, just to get more parts out of the way
Discovered a fair amount of gunk and surface rust on the shims and spring in the advance mechanism! Ew!
Now to get that roller carrier out, you need use a pick or something like it to take that little clip off of the actuator pin, located at the bottom center of the carrier. Be careful! It wants to fly off!
You will then gain access to this little lock pin. It didn't want to come out with a magnet but needle nose pliers pull it out just fine.
Te actuator pin is pretty snug too but you can sneak it out gently with some needle nose as well. The advance piston will come right out, however, you CANNOT get the carrier out without taking out the governor levers. You CANNOT take out the governor levers without taking out those goofy triangular bolts on the sides of the pump. You CAN make your own socket to get those silly bolts out
I took an extra 13mm socket and ground down 3 sides until it fit over the bolt head. Hazaa!
The carrier and main shaft come right out after that. Don't loose that little woodruff key!
I noticed right away after I took those parts out that there was some abnormal wear on the inside of the cylinder walls. I am not going to stress about it but I was a bit shocked when I saw it.
Moving on, the rotor cover in my pump only has two little phillips screws in it. Don't use a cheap screwdriver because you don't want to strip these!
I pulled this out only to find that this chamber was a MESS! All of the vanes in my rotor were rusted, crusted and seized! Everything was covered in rust and varnish! I couldn't even get the stator out of the pump body! soaked it all in WD over night so hopefully things have loosened up. I plan on wet sanding all of these parts on a flat piece of glass with a very fine piece of sand paper. I sure hope that all of this goes back together nice and smooth!
Does anybody have all of the torque specs for this pump??? Tintin posted pics at the end of veeman's walkthrough but imageshack removed them!!!!!! Any help or advice is appreciated as always