The evaporator went out on my daughter's 92 300D so she is giving it back to me. I am planning to take on that ugly job with the help of postings here on the forum when it cools off enough to work on the car.
In the meantime, I need to fix leaks on the injection pump. The car runs great (29 to 33 MPG) so if possible I want to avoid removing the pump.
My question is which gaskets and o rings can be replaced with the pump in place?
I have already replaced the o ring that seals the shaft of the manual shut off lever using one of the o rings that comes with a fuel filter.
Most of the leaking appears to be coming from where the injection lines attach to the pump. I have checked the tightness of all of the fittings and it is OK. Looking at the parts diagram there is a part called a pressure valve o ring. Is that what seals the injection line connections to the pump?

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Tom Hughes
St. Louis
84 300SD
92 300D
86 300SDL

93 300D 2.5L Injection Pump seals

93 300D 2.5L Fuel leak

Sixto
95 S420
87 300SDL

Thanks for your response. I had done a couple of searches but didn't use the right words so I did not find the two threads you sent me. They sound like the answer to my problem.
My question is does anybody know where to get the spline socket and what are the specifications on it?

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Tom Hughes
St. Louis
84 300SD
92 300D
86 300SDL

I got mine on ebay, I think relatively cheap. Do a search on MB tools or spline socket and you can come up with it.

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Keep everything as simple as possible-but no simpler--Albert Einstein

I got mine from Phil at Fastlane via this web site

I used the torque settings and it leaked , so I replaced seal again and snugged it up

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2000 Ford 7.3 Powerstroke 4x4
2006 Mazda Tribute
1983 Black 300 D (donated to charity)
1993 Teal 300 D (160K) Sold
"I love the smell of burnt diesel fuel in the morning, it smells like ....VICTORY"

Semper Fidelis
USMC 1973-1976

I got the delivery valve O rings and copper washers from Phil and replaced them using the instructions from the forum. The pump is dry on top now but it still leaves a puddle of diesel on the garage floor when I park it overnight. I can't find the leak. It does not appear to be leaking from any of the fittings and I have replaced all of the rubber fuel lines. As near as I can tell, the fuel appears to be leaking from the bottom of the pump.

Has anybody replaced the gasket at the bottom of the pump (on a 601,602 or 603) with the injection pump in place? Are there any other gaskets and O rings that I can replace without removing the injection pump?

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Tom Hughes
St. Louis
84 300SD
92 300D
86 300SDL

The IP is lubricated with engine oil. If it's leak is fuel, check the fuel thermostat behind and just below the IP. It could be a bad hose or a bad thermostat seal or nipple. You can get individual parts for the thermostat.

Sixto
95 S420
87 300SDL

Sixto:
Thanks for pointing me in the right direction. After reading your post I slipped a dry paper towel under the thermostat housing. It was soaked in a short time.
The thermostat seal was probably leaking slightly until I changed all of the fuel lines while I was in there replacing the delivery valve seals. Changing the lines got it "stirred up" and now it is leaking like crazy.
The dealer is going to get all of the seals here tomorrow so I should be fixed up soon.
I'll let everyone know how it turned out

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Tom Hughes
St. Louis
84 300SD
92 300D
86 300SDL