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OK, I need an injection pump element 101 lesson...
E300TSC Offline
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#1
Question  OK, I need an injection pump element 101 lesson...
So, I'm just going to go wild and swap my pump elements myself. I have a total of 12 cam rollers of various sizes to adjust the port closure/start of delivery.

Should I:

1. Just swap the elements and leave the cam rollers the same.

Or

2. Swap the elements and choose a selection of cam rollers that is even as possible.

I realize this is just blindly swapping parts but I'm looking for a best course of action to reach a baseline.

Now, my second question:

If the pump has a balanced delivery but the port closure/start of delivery is wrong, will adjusting the port closure/timing effect the volume from that element?

How about the reverse. If the port closure/start of delivery is balanced but the volume is not, will balancing the volume effect the other adjustment?

Thanks!
1998 MB E300 - 194,000 miles. Current/future mods: 7.5mm pump elements, Holset HX40 Turbo feeding Eaton M90 supercharger through custom fabbed intake system. Aeroturbine muffler, scratch-built 4" stainless exhaust. EGR eliminated, ECM recalibrated, modified rack position feedback circuit. Porterfield RS brake pads, Bilstein sport shocks, VDO EGT, oil and boost gauges.

2000 Ford F250 - 150,000 miles. Current/future mods: DP Tuner 3 map chip, scratch-built high flow intake, high output IDM, open circuit fuel system, ball bearing turbo, South Bend full metal clutch, slotted and drilled rotors. Autometer Sport Comp EGT and boost gauges.
04-14-2011, 08:22 PM
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garage Offline
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#2
RE: OK, I need an injection pump element 101 lesson...
Wich elements are you going to swap in?
1987 300D: EGR Delete, ARV Delete, Cold Air Intake...
04-14-2011, 09:08 PM
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300D50 Offline
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#3
RE: OK, I need an injection pump element 101 lesson...
If your port closeure is not exactly phased, your per-cylinder timing goes off the wall, which is a bad thing.

If your quantity is off, you get mismatched power, excess vibration, and etc. Also a bad thing.

Changing a plunger/barrel assembly nukes both of those adjustments.

Best bet is to get the Bosch MW 6 cylinder service manual that's floating around, read it, and get a feel for it all.
There's also some service training slideshows floating around on the governor, and what it all does. With luck, we'll have a less grey-area resource on the governor soon.

1990 Power Ram 50 V6 SOHC 24V 6g72

I can be wrong, don't take everything I say as verbatim, please fact-check first.
My posts are my personal opinions and thoughts, unless otherwise noted.
04-14-2011, 09:54 PM
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E300TSC Offline
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#4
RE: OK, I need an injection pump element 101 lesson...
This is the electronic pump so no governor to worry about. I'm familiar with the individual effects of each of the 2 adjustments. My main questions besides 1 and 2 above are:

Does the port closure adjustment effect quantity and vice versa?

If so, how?
1998 MB E300 - 194,000 miles. Current/future mods: 7.5mm pump elements, Holset HX40 Turbo feeding Eaton M90 supercharger through custom fabbed intake system. Aeroturbine muffler, scratch-built 4" stainless exhaust. EGR eliminated, ECM recalibrated, modified rack position feedback circuit. Porterfield RS brake pads, Bilstein sport shocks, VDO EGT, oil and boost gauges.

2000 Ford F250 - 150,000 miles. Current/future mods: DP Tuner 3 map chip, scratch-built high flow intake, high output IDM, open circuit fuel system, ball bearing turbo, South Bend full metal clutch, slotted and drilled rotors. Autometer Sport Comp EGT and boost gauges.
04-15-2011, 07:34 PM
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300D50 Offline
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#5
RE: OK, I need an injection pump element 101 lesson...
I'm not sure if they do, but you don't want to try running with bad phasing, at best performance would be crud, at worst, it could cause damage.
1990 Power Ram 50 V6 SOHC 24V 6g72

I can be wrong, don't take everything I say as verbatim, please fact-check first.
My posts are my personal opinions and thoughts, unless otherwise noted.
04-15-2011, 09:55 PM
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winmutt Offline
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#6
RE: OK, I need an injection pump element 101 lesson...
Port closure adjustment, this is rotating the element? If so that controls volume. Height controls timing. Atleast on the MW pump. I assume it is much the same on the M as the basic operating principal is the same.
1987 300D Sturmmachine
1991 300D Nearly Perfect
1985 300D Weekend/Camping/Dog car
1974 L508D Motoroam Monarch "NightMare"
OBK #42
04-19-2011, 09:18 AM
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300D50 Offline
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#7
RE: OK, I need an injection pump element 101 lesson...
Dur, I got them mixed up...
1990 Power Ram 50 V6 SOHC 24V 6g72

I can be wrong, don't take everything I say as verbatim, please fact-check first.
My posts are my personal opinions and thoughts, unless otherwise noted.
(This post was last modified: 04-19-2011, 09:23 AM by 300D50.)
04-19-2011, 09:23 AM
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winmutt Offline
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#8
RE: OK, I need an injection pump element 101 lesson...
I have 2 spare broken pumps. Planned on learning to do it myself as well.
1987 300D Sturmmachine
1991 300D Nearly Perfect
1985 300D Weekend/Camping/Dog car
1974 L508D Motoroam Monarch "NightMare"
OBK #42
04-19-2011, 01:53 PM
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E300TSC Offline
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#9
RE: OK, I need an injection pump element 101 lesson...
The height/roller size controls timing. Rotation/position of the holders on the rack determines volume. I'm trying to figure out if one effects the other and to what extent.

I'm leaning towards leaving everything set as is and trying it out for size.

I'm also building a simple test rig for these two adjustments so eventually, I'll be able to adjust them myself.
1998 MB E300 - 194,000 miles. Current/future mods: 7.5mm pump elements, Holset HX40 Turbo feeding Eaton M90 supercharger through custom fabbed intake system. Aeroturbine muffler, scratch-built 4" stainless exhaust. EGR eliminated, ECM recalibrated, modified rack position feedback circuit. Porterfield RS brake pads, Bilstein sport shocks, VDO EGT, oil and boost gauges.

2000 Ford F250 - 150,000 miles. Current/future mods: DP Tuner 3 map chip, scratch-built high flow intake, high output IDM, open circuit fuel system, ball bearing turbo, South Bend full metal clutch, slotted and drilled rotors. Autometer Sport Comp EGT and boost gauges.
04-19-2011, 04:11 PM
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winmutt Offline
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#10
RE: OK, I need an injection pump element 101 lesson...
And you are taking many many many pictures right Big Grin
1987 300D Sturmmachine
1991 300D Nearly Perfect
1985 300D Weekend/Camping/Dog car
1974 L508D Motoroam Monarch "NightMare"
OBK #42
04-19-2011, 04:32 PM
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winmutt Offline
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#11
RE: OK, I need an injection pump element 101 lesson...
I started dismantling one of my pumps last week. I got the governor off which was amazingly easy.
1987 300D Sturmmachine
1991 300D Nearly Perfect
1985 300D Weekend/Camping/Dog car
1974 L508D Motoroam Monarch "NightMare"
OBK #42
04-27-2011, 08:02 AM
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dieselmeken Offline
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#12
RE: OK, I need an injection pump element 101 lesson...
Time for me to do a video on the M-serie?
05-06-2011, 01:34 AM
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E300TSC Offline
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#13
RE: OK, I need an injection pump element 101 lesson...
Yes! That would be very helpful! Here are some pictures I took of the tools I made to service the pump. They are just rough prototypes so don't be too hard on me! Smile

Tool for compressing element springs/rollers:

[Image: P4120177.jpg]

[Image: P4120175.jpg]

Stabilizer for element locking pins:

[Image: P4120178.jpg]
1998 MB E300 - 194,000 miles. Current/future mods: 7.5mm pump elements, Holset HX40 Turbo feeding Eaton M90 supercharger through custom fabbed intake system. Aeroturbine muffler, scratch-built 4" stainless exhaust. EGR eliminated, ECM recalibrated, modified rack position feedback circuit. Porterfield RS brake pads, Bilstein sport shocks, VDO EGT, oil and boost gauges.

2000 Ford F250 - 150,000 miles. Current/future mods: DP Tuner 3 map chip, scratch-built high flow intake, high output IDM, open circuit fuel system, ball bearing turbo, South Bend full metal clutch, slotted and drilled rotors. Autometer Sport Comp EGT and boost gauges.
05-06-2011, 01:34 PM
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George3soccer Offline
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#14
RE: OK, I need an injection pump element 101 lesson...
Pretty awsome stuff, kep us updated all the time. Would love to hear from Dieselmeken and from you, e300TSC.
Mb 1984 w201 om603 swap.
Mb 1986 w201 190E 2.3-16v
Mb 2004 w203 C230k
05-08-2011, 03:48 PM
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winmutt Offline
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#15
RE: OK, I need an injection pump element 101 lesson...
So when you gonna start offering a service state side Big Grin
1987 300D Sturmmachine
1991 300D Nearly Perfect
1985 300D Weekend/Camping/Dog car
1974 L508D Motoroam Monarch "NightMare"
OBK #42
05-09-2011, 08:48 AM
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E300TSC Offline
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#16
RE: OK, I need an injection pump element 101 lesson...
Ha! Maybe for the electronic pumps since there's much less "art" involved in the swap. No governor or other settings to worry about.
1998 MB E300 - 194,000 miles. Current/future mods: 7.5mm pump elements, Holset HX40 Turbo feeding Eaton M90 supercharger through custom fabbed intake system. Aeroturbine muffler, scratch-built 4" stainless exhaust. EGR eliminated, ECM recalibrated, modified rack position feedback circuit. Porterfield RS brake pads, Bilstein sport shocks, VDO EGT, oil and boost gauges.

2000 Ford F250 - 150,000 miles. Current/future mods: DP Tuner 3 map chip, scratch-built high flow intake, high output IDM, open circuit fuel system, ball bearing turbo, South Bend full metal clutch, slotted and drilled rotors. Autometer Sport Comp EGT and boost gauges.
05-10-2011, 05:27 AM
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winmutt Offline
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#17
RE: OK, I need an injection pump element 101 lesson...
? Dont you still need to adjust the individual fuel quantity on the rack?
1987 300D Sturmmachine
1991 300D Nearly Perfect
1985 300D Weekend/Camping/Dog car
1974 L508D Motoroam Monarch "NightMare"
OBK #42
05-10-2011, 09:14 AM
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E300TSC Offline
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#18
RE: OK, I need an injection pump element 101 lesson...
Yes, the quantity and the individual timing. I can do both but I need to devise a test rig.
1998 MB E300 - 194,000 miles. Current/future mods: 7.5mm pump elements, Holset HX40 Turbo feeding Eaton M90 supercharger through custom fabbed intake system. Aeroturbine muffler, scratch-built 4" stainless exhaust. EGR eliminated, ECM recalibrated, modified rack position feedback circuit. Porterfield RS brake pads, Bilstein sport shocks, VDO EGT, oil and boost gauges.

2000 Ford F250 - 150,000 miles. Current/future mods: DP Tuner 3 map chip, scratch-built high flow intake, high output IDM, open circuit fuel system, ball bearing turbo, South Bend full metal clutch, slotted and drilled rotors. Autometer Sport Comp EGT and boost gauges.
05-10-2011, 04:03 PM
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E300TSC Offline
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#19
RE: OK, I need an injection pump element 101 lesson...
Continuing on with this project, I have another question. When checking timing, how much pressure dues it take to "crack" the delivery valves and cause fuel to drip?
1998 MB E300 - 194,000 miles. Current/future mods: 7.5mm pump elements, Holset HX40 Turbo feeding Eaton M90 supercharger through custom fabbed intake system. Aeroturbine muffler, scratch-built 4" stainless exhaust. EGR eliminated, ECM recalibrated, modified rack position feedback circuit. Porterfield RS brake pads, Bilstein sport shocks, VDO EGT, oil and boost gauges.

2000 Ford F250 - 150,000 miles. Current/future mods: DP Tuner 3 map chip, scratch-built high flow intake, high output IDM, open circuit fuel system, ball bearing turbo, South Bend full metal clutch, slotted and drilled rotors. Autometer Sport Comp EGT and boost gauges.
08-28-2011, 06:40 AM
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dieselmeken Offline
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#20
RE: OK, I need an injection pump element 101 lesson...
(08-28-2011, 06:40 AM)E300TSC Wrote: Continuing on with this project, I have another question. When checking timing, how much pressure dues it take to "crack" the delivery valves and cause fuel to drip?

App 25 bar inletpressure.

09-29-2011, 05:38 AM
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