Rebuilding the BOSCH diesel injection pump.
There is at least one customer per week asking if this is DIY.
ANSWER: This is not a DIY job on a Mercedes, ever...

I found a local (Detroit, Michigan) BOSCH diesel injection repair shop, happy to cooperate in making this video.
Superior Turbo and Injection
http://superiorturbo.com/

Here are some pictures of the basic calibration and test stands needed to rebuild the BOSCH diesel injection pump correctly.

The shop owner allowed me in to take these pictures.

The cheapest machine is $148,000.00 USD..

Attached Thumbnails

         

input or suggestions are welcome

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We have Final approval, it is now a matter of fitting it into the repair shops busy schedule.

The video shoot is tentatively planned for some time in the next thirty five days.

Rough program layout:

* Make a video of the total process.
* How the injection pump can be damage while it is off the engine.
* Packaging and shipping, how to send it to a re-builder.
* Bring in four OM617 injection pumps for cleaning - testing.
* Their expert interprets the results with possible causes of any issues.
* Forensic - diagnostic tear-down, showing and explaining all issues found.
* Step by step description of the repair process with tool display.
* Calibration.
* Packaging and shipping, what you should receive back from a re-builder.
* How to put a good used or rebuilt unit in storage, and how long will it survive on the shelf?
* Send a copy of the completed video to webmaster for best forum post, resolution, access.

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Supplies:
I have a total of four dead OM617 units, three may be stuck delivery valves (on the shelf too long).
One is from a 300D junked last year.
We found over one gallon of water in the filters, lines and fuel tank.
The previous owner admitted (experimenting) pumping unfiltered WVO from a restaurant grease trap directly into the fuel tank, for three months before giving me the dead car.

Do you have:

Any question you would like asked/answered by BOSCH diesel injection pump experts on the video.

Any specific focus diesel injection pump area - angle picture you would like to see on the video.

It really seems to me that there are mixed messages being sent here...
I have seen Randy's IP manual... I totally agree it is not a DIY rebuild situation ... ever... period...
So are you thinking of making the video just for grins.. or to impress others with the fact that it is NOT a DIY job...
But most videos on stuff like this are for showing people how to DIY...
So I am a bit confused...

I want to make this video as FYI:

99% of all diesel injection pump damage is internal = the only way to show it involves a forensic tear-down.

It will also prove beyond argument that this is not a DIY = Send a copy of the completed video to webmaster for best forum post, resolution, access.

There are many questions that can be answered in the process..


* How the injection pump can be damage while it is off the engine.

* Packaging and shipping, how to send it to a re-builder.

* Their expert interprets the results with possible causes of any issues.

* Forensic - diagnostic tear-down, showing and explaining all issues found.

* Step by step description of the repair process with tool display.

* Calibration.

* Packaging and shipping, what you should receive back from a re-builder.

* How to put a good used or rebuilt unit in storage, and how long will it survive on the shelf?

This is a really great topic. I and Im sure many others will be very interested. I believe that it is not a DIY job, but am very curiuos nevertheless.

Good Idea for FYI for those who are interested. What did they charge for a rebuild?

__________________
1982 300SD

Sounds good.

so can i send my m-pump for a myna treatment at the same time...
Is the video going to be available here?

__________________
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Aquilae non capunt muscas! (Eagles don't hunt flies!)


1979 300SD Black/Black MBtex239000mi
1983 300TD euro-NA. White/Olive Cloth-MBtex 201000mi. Fleet car of the USA embassy in Morocco
1983 240D Labrador Blue/Blue MBtex 161000mi

They are doing all of this gratis = for the local advertising.
Send me your phone number, on the ip repair cost question.

Perhaps I should emphasize this a little.
I will send a copy of the completed video to webmaster@peachparts.com to post for members, (he will decide where and how, resolution, etc).

Brilliant.

__________________
1987 300D (230,000 mi on a #14 head-watching the temp gauge and keeping the ghost in the machine)
Raleigh NC - Home of deep fried sushi!

Waiting w/ baited breath. (Had fish for dinner) No really, this stuff is better than a night @ the theater for me.

Thanks for your efforts, I'd really like to learn more about what makes these injection pumps work.

__________________
95 E300 Diesel 265k and counting

I'd like to know what would happen if one sat too long on a shelf. I've got three of them.

__________________
DJ


84 300D Turbodiesel 190K with 4 speed manual sold in 03/2012

Nightmare trying to work around everyones work schedule..

We are still trying to get this wrapped up, but doubt it will be done before February/March of 2010...

A great project whunter!!
Maybe worth a mention of pitfalls putting it back on the engine. Checking injector timing etc.
Anything that demystifies IP's is a good thing!

__________________
Grumpy Old Diesel Owners Club group

I no longer question authority, I annoy authority. More effect, less effort....

1967 230-6 auto parts car. rust bucket.
1980 300D now parts car 800k miles
1984 300D 500k miles
1987 250td 160k miles English import
2001 jeep turbo diesel 130k miles
1998 jeep tdi ~ followed me home. Needs a turbo.
1968 Ford F750 truck. 6-354 diesel conversion.
Other toys ~J.D.,Cat & GM ~ mainly earth moving