Injection pump replacement.

More threads by abl567

abl567

Super Moderator
Moderator
Messages
2,169
Points
240
Location
Sydney
Just before the M100 rally the fuel injection pump on my 6.3 started to leak internally and overfill the govenor part of the pump, this results in rich running and oil running out of the pump filler tube into the valley of the engine and then onto the driveway or the hot exhaust when you plant your foot. I cured the symptom for the rally by running a oil bypass line from the injection line filler tube to the dipstick tube, needless to say that got me through the rally but it was time to fix it properly.
I decided to install the spare pump I bought from a M100 club member many months ago so today removed the existing pump, it wasn't that hard really, no that is a lie it was bordering on self harm but worth it

Some pics

Left inlet manifold, injectors and injection lines. the parts in the bottom of the box are the throttle linkage

101_1168.jpg

The empty valley
101_1166.jpg

Old pump

101_1169.jpg

New pump ready for install

101_1170.jpg

This is all the fastners I had to remove to get this far, it is unbelievable how well designed these cars are.

101_1171.jpg
 
Last edited:

Michel

The Prince of Arabia
Moderator
Messages
10,016
Points
775
Location
Sydney, Australia
great photography so far..
any more pics coming up?
 

Parks

New Member
Messages
240
Points
0
Location
Sydney
I dont envy you Anthony, its a mongrel of a job Ive seen styria do it numerous times:eek:
 

WGB

New Member
Messages
1,289
Points
0
Location
Perth Western Australia
So when I buy my 6.3 I'm looking for one with a new Injector pump as well as a new water pump:D

Thanks for the photo's I forget that the 6.3 had a mechanical injection pump.

The normal injection pumps for Diesels can be rebuilt - does that apply to the 6.3 one as well?

Bill
 
OP
abl567

abl567

Super Moderator
Moderator
Messages
2,169
Points
240
Location
Sydney
So when I buy my 6.3 I'm looking for one with a new Injector pump as well as a new water pump:D

Thanks for the photo's I forget that the 6.3 had a mechanical injection pump.

The normal injection pumps for Diesels can be rebuilt - does that apply to the 6.3 one as well?

Bill

Yes Bill the pumps can be rebuilt, Neil Dubey of Star Motors has insisted he will provide me with rebuilt pump rather than use a local rebuilder, I have the old pump almost ready to crate up and send to Neil.

In the mean time I'll install the spare pump shown and see how it runs, I've sealed up all the gaskets on the spare pump and now need to make some paper gaskets for where the pump bolts to the block.
 

WGB

New Member
Messages
1,289
Points
0
Location
Perth Western Australia
Thanks for that.

I think there is room for another car in a couple of years and the 6.3 is one on the short list of possibles.

I guess the 6.9 K-jet in good working order is about as simple as you can get so anything else is going to hurt a bit more to fix.

Bill
 

Styria

The Godfather
Moderator
Messages
9,364
Points
492
Location
Sydney
Hi Anthony, from what I seem to recall, the pump you are about to despatch to the States was, in fact, reconditioned by Star Motors.

As you know from records that you have, your car has recorded a low mileage only, and it seems somewhat unusual that the pump and, for that matter, any other engine or headwork needs to be undertaken.

Then again, as you would be aware, your car has had a pretty 'bumpy' ride, so God only knows what has transpired in the last four to five years.

You did very well removing the pump that quickly - three hours I believe. I am just trying to figure out now how you managed to get sections of the pump past the inlet manifold on the right hand side. Anyway, whichever, a sterling job considering your garaging facilities and the sheer weight of manhandling the pump. Keep us posted and informed as to how you get on. Regards Styria
 
OP
abl567

abl567

Super Moderator
Moderator
Messages
2,169
Points
240
Location
Sydney
Hi Styria, I'm sure you have heard of the garages kill theory when it comes to 6.3's, they need to be driven or they deteriate rapidly. I've noticed on the old pump that 3 of the 8 injector elements are discoloured where the injector line fits to the pump and the fuel return line is also discoloured. This I believe indicates the seals at the bottom of these pump elements have failed allowing oil to mix with the fuel and overfilling the pump govenor. It may also explain the symptoms that indicate faulty valve seals, if the fuel charge to 3 cylinders is oil laden it makes sense to me the engine would show oil burning on the overrun as the pump has little call for fuel but the oil is still entering the element under pressure. It may be wishfull thinking but I'll see what happens when I get the new pump in.
You are so right about manhandling the pump, they are heavy buggers, It seems to work on a 6.3 you need to be skinny and weedy but with weightlifter strength, still working on the latter...
 
Similar threads
Thread starter Title Forum Replies Date
abl567 Injection pump replacement. Part 2 Talking Torque 3
Styria 6 cyl. (Pagoda) Injection Pump Articles 0
Styria Servicing 6.3 Injection Pump Mercedes W108 and W109 2
S Direct injection Articles 1
J Bosch D-Jetronic Fuel injection 1974 280 SE W116 Articles 17
Tony66_au D-Jet Injection system. Technical Information 17
Styria Early 6 cylinder fuel injection Articles 0
Styria K-JET Injection system Technical Information 12
hoddo water/methanol injection Talking Torque 4
Oversize Fuel Pump Relay $$ Outrage Talking Torque 7
Styria Power Steering Pump Technical Information 1
Styria 6.9 Water Pump replacement Technical Information 35
A water pump Mechanicals 7
Oversize Fuel pump safety cutout Mechanicals 5
Oversize 450 fuel pump relay Technical Information 10
L Water Pump Flow Rate Mechanicals 19
Oversize Petrol pump cutout Mercedes W116 1
MercedesMike 6.9 Transmission Pump Mechanicals 8
SELfor50 6.9 Suspension Pump - New (almost un-used) Gumtree/eBay/Facebook Listings 12
Styria 6.9 water pump housings Mechanicals 1
Styria 6.9 water pump removal Mechanicals 4
J Last rites for a fuel pump Mechanicals 0
M The Chronicles Of Mercules - Water Pump Mechanicals 12
Styria 6.9 Water Pump Removal Mechanicals 4
B Which Bosch fuel pump do I need for my 450SE D-Jet 1975 Mechanicals 1
TJ 450 Washer pump removal on 6.9 Mechanicals 3
Oversize Replacement Wheels & Cleaning Exteriors and Body Repairs 3
Styria 6.9 Carpet Replacement Interiors 1
Oversize Suggestions for a daily replacement Talking Torque 20
c107 Monovalve replacement Mercedes W126 0
S Air Bag Replacement Mechanicals 9
4 450SEL Hood Pad replacement Exteriors and Body Repairs 23
L Clock Replacement Mechanicals 5
A Soft Top Replacement Mercedes R/C107 3
AM1961 Inertia Reel Seat Belt Replacement Interiors 18
WGB Rear 6.9 upper strut mount replacement Technical Information 0
WGB Rear sway bar chassis bush replacement Technical Information 0
WGB RH Sway bar chassis bush replacement in RHD 6.9 Technical Information 0
WGB Rear Screen removal and replacement Interiors 2
WGB M117 Timing Chain Replacement - Pictorial Technical Information 11
abl567 6.3 Camshaft replacement Mercedes W108 and W109 0
WGB Pictorial - Rear End Rebuild Part 7 - Diagonal arm bush replacement Technical Information 1
WGB Pictorial - Rear end rebuild Part 3 - Pinion seal replacement. Technical Information 0
Styria Replacement of four doors - 6.9 Technical Information 25
Styria Replacement of Air Con hose Mercedes W116 0
Styria 6.9 front suspension valve replacement Mercedes W116 12
J 6.9 Air cells check & replacement Mechanicals 8
BenzLover Engine radiator replacement Mechanicals 3
G seeking replacement front grill for w116 450SEL 1979 Gumtree/eBay/Facebook Listings 10
A Aircond compressor replacement Mercedes W116 32

Similar threads

Top