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ALLDATAdiy.com - 1983MercedesBew240D (123.123)L4-2.4LDSL(616.912) - PistonT

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WelcomeRICHARDMAY

Leadingsourceof OnlineDiagnostic& RepairInformation

YourVehicle:1983MercedesBenz240D(123.1231L4-2.4LDSL(6f6.9{2)

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Fig. I Fabricatedvacuumpump iesting adapter

TESTING

> Serviceand Repair> PistonTvpe

Notes

1. Usingfabricatedadapter,Fig.l, connectsuitablevacuumgauge tovacuumlinebetweenbrakeboosterandcheckvalve.

2. Startengineandrunat 750RPMandnotetengthoftimerequiredto obtain14.8inchesHgv6cuum.

3.

OnmodelsequippedwithI

vacuumaccessori€sventedand9-11

booster,elapsedtimeshouldmeasure '12-13 secondswithbrakeunitandallvacuumaccessbriesventedand7-dsecondsiith unitonlyvented.

lf elapsedtimeis notwithinspecificationsor if

necessary.

lf no leaksarefound,repairor replacevacuumpumpas

inchdoublediaphragmbrakebooster,elapsedtimeshouldmeasure13-14secandswithbrakeunitandall

secondswithbrakeunitonlyvented.Onmodelsequippedwith1Oinchsinglediaphragrnbrake

brate

vacuumdropsmorethan5.9inchesHgin 30seconds,checkvacuumsystemfor leaks.

4,

REMOVAL

4

1-

Disconnec{vacuumlinefromvacuumpump.

Removevacuumpump attachingbolts,thenthevacuumpump andgasket, Fig-3,fromcrankcase.

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1983MercedesBenz240D {123.123)L4-2.4L DSL(616.912) - PistonT

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Fig.3 Pistontype vacuumpump

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DISASSEMBLY

t. Securevacuumpump in holdingfixtureNo.115589142100orequivalent,withfixturespindlecompletelybackedout.Castingseam on vacuumpump must be centeredbetweenthe two fonrard acrewsof holdingfixture.

2. Movepiglg

3. Removepump coverattachingscrewsandthecover.

4. Removepump covergasket,thenthegasketsandplatevalvesfromhousing.

5. Removelocknutandwasherfromoistonrod.

6. Fullybackoutholdingfixturespindle,thenremove piston fromhousingusingsuitablepliers.

7. Removeoistondiscfrompumphousing,thenthe piston rinqandO-ringfrompiston.lf piston liner shows signs of wear,the

rodandpiston to TDCposition byturningholdingfixturespindleupto stop.

vacuumpump must be replaced.

8. Removerockerarmshaftplugfromhousing.

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0lt"

Fig.4 Fabricatedpiston rod tool. Plstontype vacuumpump

9. Screwfabricatedtool,Fig.4, into pigton rod.Tumdownnulto compressspring,thenremove pump fromholdingfixture.
10.

Removeshaft,thenthe pistonrod,springassemblyrockerarmandfabricatedtoolfrompumphousing.

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ALLDATAdiy.com - 1983MercedesBenz24AD 023.123)L4-2.4L DSL(616.912) -

PistonT

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11. Backtooloul of piston rod,thenremovespringretainerandsprings.Therockerarm and piston must beservicedas an assembly only.

ASSEMBLY

1

Positionspringretainerandspringson

Installrockerarmshaftintopumphousing.

piston rod.Compressassemblywithfabricatedtool,Fig.4,theninstallintopumphousing.

rodfl-nge is centeredin upperspringretainer.

2.

3.

4.

5- Thoroughlycleanoiston,thenlubricateandinstallnewO-ringandpistonring.

6.

7.

8.

9.

4pply

Securepump to holdingfixtureandturnholdingfixturespindleupto

suitablelockingcompoundto rockerarmshaftplug,theninstallplugwithnewsealandtorqueto 6-7ft. lbs.

stop,thenremovefabricated'tool.

rodupto stopusinghotdingfixturespindle.Ensure piston

usingcareto avoiddamagingbistonring.

Push piston

Positionpiglon discon pistonrod,thenlighilylubricatepistonliner.

lnstall Eg!q,

lnstallwasherandlocknuton piston

Installplate valvesandnewgasketsintopumphousing.

Installpumpcoverandtorqueattachingscrewsto

Removevacuumpumpfromholdingfixture.

rod.Backoutspindleandbottompiston outagainsthousing,thentorquelocknutto 7 ft. lbs.

2 ft. lbs.

10.

11.

12.

INSTALLATION

1. lnstallvacuumpumpto

crankcaseusinga newgasket, thentightenattachingboltssecurely.

2. Connectvacuumlineto pump.

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