1974 240D wont start - Page 2 - Mercedes-Benz Forum

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post #11 of 16 (permalink) Old 01-14-2012, 02:56 AM
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Nothing should come out of the hard lines when you use the hand pump. The hand pump is only there to fill the fuel filter and fuel chamber of the IP. After that the IP takes over. It can take a while to start if the hard lines are empty and some people leave them open at the injector until fuel comes out, but that is not really necessary.

The pressure relief valves open at about 70 bar pressure (1015 psi), so the hand pump cannot open them.

The pressure relief valves are best left in place, because when you open the valve holders, you have to renew the copper washer, otherwise it will leak internally. These are special copper washers, you cannot use generic ones. They are not expensive luckily. Get them at the dealer or specialised diesel shop. There are rubber O rings which can get damaged too and must in that case be replaced.

Special care should also be taken to the correct torque of the valve holders: First 30 Nm and loosen, 30 Nm again and loosen, then torque to 35 Nm and you are done. If overtorqued, the pump housing can get damaged or it can leak.
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post #12 of 16 (permalink) Old 01-14-2012, 03:02 AM Thread Starter
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so I decided to clean up the IP before reinstalling everything, I guess I got a little carried away taking parts off to clean them on my bench. Well I found a series of cracks on the inside of the fuel filter cap along the bolt hole, that should be the cause of the hissing sound (I hope) and I ordered all kinds of new seals from autohausaz. Most of banjo fittings were missing one or both of the copper seals. If any one wants pictures of any of the parts this would be a good time everything is clean and polished.
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post #13 of 16 (permalink) Old 01-14-2012, 07:22 PM Thread Starter
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Well I can't find a new fuel filter cap online, I have a local European only yard that I am going to call monday, the local dealer wants $500.00 to have a custom one made in Germany. Any one have a source for one?
Also can I use RTV for the lift pump gasket?
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post #14 of 16 (permalink) Old 01-21-2012, 03:53 PM
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Wow, I was just trying to find a simple cure for my 79 240D and its no fuel pressure. Funny how I ran in to your thread. Hope that fuel filter cap I almost scrapped fixes your issue!
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post #15 of 16 (permalink) Old 01-21-2012, 04:02 PM Thread Starter
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I hope so too I has been raining or snowing this weekend so I haven't been able to fix it yet
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post #16 of 16 (permalink) Old 01-23-2012, 05:43 PM Thread Starter
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Well I got everything put back together today with new seals, gaskets and fuel filter cap, but of course to change in the car. I also loosened up the hardlines at the injectors and put jars under them, when I tried to start the car I had fuel come out. My next guess is there is a problem with the injectors themselves, probably my fault when I rebuilt them. Next weekend I am going to remove the injectors and try to see if they squirt when I turn the engine over.
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