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YourVehicle: 1983Mercedes Benz240D(123.1231L4-2.4L DSL(6f6.9{2)

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Notes

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Fig. I Fabricatedvacuum pump iesting adapter

TESTING 1. Usingfabricated adapter, Fig. l, connect suitable vacuumgaugeto vacuumline between brakebooster and checkvalve. 2. Startengineand run at 750RPMand notetengthof time required to obtain14.8inchesHg v6cuum. 3. On modelsequipped with I inchdoublediaphragm brakebooster, elapsed time shouldmeasure 13-14secands with brakeunitand all vacuumaccessoris ventedand 9-11 seconds with brakeunitonlyvented.On modelsequipped with1Oinchsinglediaphragrn brake '12-13 booster, elapsedtimeshouldmeasure seconds with brakeunitand all vacuumaccessbries ventedand 7-d seconds iith brate unitonlyvented. 4, lf elapsed time is notwithinspecifications or if vacuum dropsmorethan5.9 inchesHg in 30 seconds, checkvacuumsystemfor leaks. lf no leaksare found,repairor replace vacuumpumpas necessary. REMOVAL
4 1-

Disconnec{ vacuumlinefromvacuumpump. Remove vacuumpumpattaching bolts,thenthe vacuumpumpand gasket,Fig- 3, fromcrankcase.

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ALLDATAdiy.com- 1983Mercedes Benz240D{123.123)L4-2.4L T... Page 2 of 3 DSL (616.912) - Piston

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Fig. 3 Piston type vacuum pump

DISASSEMBLY
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2. 3. 4. 5. 6. 7. 8.

vacuumpumpin holding Secure fixtureNo. 115589142100 or equivalent, withfixturespindlecompletely backedout.Castingseam on vacuum pump must be centeredbetweenthe two fonrard acrews of holding fixture. Movepiglg rod and pistonto TDCposition fixturespindleup to stop. by turningholding pumpcoverattaching Remove screwsand the cover. pumpcovergasket,thenthe gasketsand platevalvesfromhousing. Remove Remove locknut andwasherfromoistonrod. pistonfromhousing Fullybackout holding pliers. fixturespindle, then remove usingsuitable Remove oistondiscfrompumphousing, thenthe pistonrinqand O-ringfrompiston.lf piston liner shows signs of wear, the vacuum pump must be replaced. rockerarm shaftplugfromhousing. Remove

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Fig.4 Fabricatedpiston rod tool. Plston type vacuum pump

9. Screwfabricated tool, Fig. 4, intopigtonrod.Tum downnul to compress fixture. spring,thenremovepumpfromholding 10. Remove shaft,thenthe pistonrod,springassembly rockerarm andfabricated toolfrompumphousing.

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ALLDATAdiy.com- 1983 Mercedes Benz24AD023.123)L4-2.4L DSL (616.912) T... Page 3 of 3 - Piston


11. Backtooloul of pistonrod,thenremove springretainer and springs. The rocker arm and piston must be serviced as an assembly only. ASSEMBLY 1 2. 3. 4. 56. 7. 8. 9. 10. 11. 12. Position spring retainerand springs on piston rod.Compress assembly withfabricated tool,Fig.4, theninstall intopumphousing. Installrockerarmshaftintopumphousing. locking compound to rockerarm shaftplug,theninstallplugwith newsealand torqueto 6-7 ft. lbs. 4pply suitable Securepumpto holding fixtureand turn holding fixturespindleup to stop,thenremove fabricated'tool. Thoroughly cleanoiston, thenlubricate and install newO-ring andpiston ring. piston Push rod up to stopusinghotding fixturespindle. Ensurepistonrodfl-nge is centered in upperspringretainer. piglondisc on pistonrod,then lighilylubricate Position pistonliner. lnstallEg!q, usingcareto avoiddamaging bistonring. lnstallwasherand locknut on pistonrod.Backout spindleand bottompistonout againsthousing, thentorquelocknut to 7 ft. lbs. platevalves Install andnewgaskets intopumphousing. Installpumpcoverand torqueattaching screwsto 2 ft. lbs. Remove vacuumpumpfrom holding fixture.

INSTALLATION
1 . lnstallvacuumpumpto crankcase usinga newgasket, thentightenattaching boltssecurely. 2. Connect vacuum lineto pump.

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