IP Full Load Adjustment Procedure for the MW and M pumps

Holset

411

03-11-2008, 08:47 PM #3

MTUPower Could you go into detail about the pulling of the IP and the re-install? Future members will want to know how to do this, and whether or not you used a lock pin to keep the IP in the correct timing.

Okay, pulling the IP is about one of the most painful things one can do on a Benz, besides trying to get the rear IP cover off without removing the oil filter housing.

To pull the IP: There is the easy way, and the hard way. I will go step-by-step through the easy way, then step-by-step through the hard way.

THE EASY WAY:

0) Set engine to TDC on the crank balancer
1) Order a filter housing gasket, and an IP gasket
2) Remove the filter housing
2a) Cut the short side of the appropriate allen wrench (possibly 6 meters, but I'm not sure) with a grinding disk, making sure to take small cuts at a time to keep it from heating up and losing its hardness. You will have to cut enough off, but not too much. To gauge how much enough is, find the hardest-to-reach allen bolt holding the filter housing to the block (the ones that go through the filter housing). It should be the one closest to the "frame" rail. Make sure you have about 1/2-3/4inch clearance between the top of the wrench and the "frame" rail.
2b)Detach the oil cooler lines
2c)Detach the oil pressure sender line, and the oil line off the rear of the filter housing (turbo oil line)
2d)Pull all the bolts holding the oil filter housing to the block. This will require some creativity with extensions, sockets, allen wrenches, etc.
2e)Lift the filter housing out
3)Remove The IP
3aa) detach all the fuel lines, injector lines, oil lines, vac lines, linkages, etc from IP
3a)Remove the rear mounting bolt from the IP, and the rear mounting bracket from the block
3b)remove the 3 nuts on the IP flange
3c)gently pull the ip back out of its hole, and lift up.

THE HARD WAY:
1) Order a new IP gasket, or don't if you are feeling lucky (please just do it, this is not a time to trust ones feelings)
2) Set engine to TDC
3) By some wonderous miracle, remove the rear cover from the IP (I have done it about 5 times now, trust me it gets easier each time)
3a) you will need some sort of fancy screwdriver with a ratchet to get at the flathead screws. Take a look before you jump in and acquire the appropriate tools
3b) you will need to remove the shutoff solenoid and the rack damper bolt before you can get anything out.
3c) once (if) you get the IP cover off, now you can remove the rear mounting bolt for the IP
4) remove the bracket from the block
5) remove the bolts from the IP flange, remove the IP as per the easy way, but its harder due to the filter housing.

Re-installing the IP:

1)Put the IP back in (with the new gasket)
2) loosely attach the 3 flange bolts
3) check, double check, and triple check your timing with the drip tool, and set your timing. If you can't get it, it means you are off a tooth or 2 on the splined collar, and you have to pull the IP out of the splined collar, rotate it either towards or away from the block (towards = advance, away = retard) nearly its entire range of motion, and stick it back in the collar. Keep rotating and checking until you get the timing right.
4)re-attatch all the parts in their correct locations.

A NOTE: Get a shop manual. It explains all this in much better detail than I am able, and it has pictures

ANOTHER NOTE: The easy way is MUCH EASIER, even though it seems more complex. Just do it the easy way, it will take less time and you will be happier afterwards.

LAST NOTE: The hard way can be made easier in the future if you replace the IP cover screws with some allen-head screws while the IP is out.

This is a miserable job to do on these cars, but if you want more fuel, you have to get used to it Smile

Also, keep a supply of oil filter housing gaskets onhand because you will likely want to mess with the torque control, which although it may be possible with the oil filter housing on the car, it is much easier and quicker to just remove the housing.

ONE LAST THING, AND ITS IMPORTANT:

AFTER RE-INSTALLING THE IP, MAKE SURE YOU FILL IT WITH THE CORRECT AMOUNT OF OIL THROUGH THE FILL PLUG!! FIND A PICTURE IN THE FACTORY SHOP MANUAL OF WHERE THE FILL PLUG IS, AND HOW MUCH OIL TO FILL IT WITH. This can be accomplished much easier with a large syringe (I used a 35cc one) with a piece of flexible hose stuck on the end.

GREASY_BEAST