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  #1  
Old 08-12-2005, 08:57 PM
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603 delivery valve seals

Hi guys,

I'm still not convinced my delivery valve project is a success just yet. I replaced them last Sun on my 87 300D and everything went well and I kept everything clean. I swear I hear a slight hammering and pinging sound at idle and you can often hear it right around 1k rpm. I replaced them because my small leak grew into a small "river" and I couldn't believe how much diesel was sitting in the lower plastic pan. Now, the car idles just fine, has relatively no smoke and has lots and lots of power! Oh, no leaks either! What gives? Do you think I should re-check my torque on the holders or simply start with injectors or just live with it since everything else is fine. I thought that improper torque or a warped pump body would offer lots of smoke, vibration and a rough idle... I have none of this. Do you think one of the seats isn't sealing properly and I'm seeing the effects or maybe I have a bad injector? It has 215k on it now and I believe was quieter and "leakier" prior to my project. Please let me know your thoughts as I haven't found anything "definitive" in my search efforts.

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  #2  
Old 08-12-2005, 11:51 PM
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any thoughts guys?
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1960 MB 190Db w/ full sunroof
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  #3  
Old 08-13-2005, 02:50 AM
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What's the condition of the clamps that keep your injector lines from touching?

Sixto
95 S420
87 300SDL
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  #4  
Old 08-13-2005, 03:10 AM
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Did you try running some Diesel Purge through the system or do an italian tuneup? How did you torque the IP elements? But I don't think that's where the fault lies. Hammering/pinging/knocking is usually caused by too much fuel being ignited at once which is usually caused by inadequate fuel dispersion and/or inadequate combustion temperature. Temperature would be related to compression and there's not much you can do about it if it's bad. But fuel dispersion is something you can address.
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Old 08-13-2005, 11:40 AM
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Quote:
Originally Posted by sixto
What's the condition of the clamps that keep your injector lines from touching?
The clamps that keep the injector lines from touching are all new and I even replaced all of the little rubber bits at the same time. Everything feels tight, secure and otherwise in place.

I tightened the elements by placing some vaseline on the threads, hand tightening them until snug, torquing them to 20 ft-lbs and then releasing, 20 ft-lbs again and releasing and finally 25 ft-lbs and holding.... It was tight in there for a torque wrench but all seemed well and I was very careful about it. Any more thoughts? Oh, I've tried the Italian tuneup and it runs like a quick 603 should run!

Also, I think compression is good because this engine starts on a dime and has zero blowby from the breather and hose...
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Old 08-15-2005, 03:47 PM
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Anyone? I still need some help with this project.... The nailing injector(s) is driving me crazy! I listened to my grandpa's 603 and his is almost silent. What went wrong? I didn't pull the entire pressure valve out of the IP... I know many have talked about orientation, etc. I simply pulled off the spring, inserted a new copper washer on top of the delivery valve and reassembled everything with the 20,20 and 25 ft-lbs. I definitely have more smoke at idle than my grandpa's and I don't know where to troubleshoot next. Should I redo the job or could I have a bad injector all of a sudden? Please help me...
GSXR???


THanks.
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2001 VW Jetta GLS TDI
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  #7  
Old 08-15-2005, 03:52 PM
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Like I said previously, try some Diesel Purge. It's possible you introduced some dirt into your fuel system while doing this job.
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Old 08-15-2005, 03:56 PM
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Thanks Dieseladdict. I guess I just need some reassurance that the job is done correctly. I'll order some diesel purge and see if it helps.
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2006 Honda Odyssey EXL R&N
2001 VW Jetta GLS TDI
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  #9  
Old 08-15-2005, 04:01 PM
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Did you replace the o-rings? In the attached picture 7h is the o-ring, 7f is the washer.

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95 S420
87 300SDL
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603 delivery valve seals-deliveryvalve.jpg  
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  #10  
Old 08-15-2005, 04:07 PM
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You should've replaced the o-rings, but if you didn't it's not a big deal as long as they don't leak. The o-rings would cause an external leak which would be visible. The copper rings would cause an internal leak which could cause problems, but I don't think knocking is one of them. Basically the affected cylinder would have delayed and reduced fuel delivery, causing smoking, rough idle, but not knocking. In fact that cylinder should be quieter as a result. The easiest thing to do at this point is to try that Diesel Purge.
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  #11  
Old 08-15-2005, 04:08 PM
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Sixto,

Yes, I replaced both the O-Rings and the copper washers. I keep wondering, however, is there a certain placement of the copper washer? I swear I don't remember a groove it would sit in....
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2006 Honda Odyssey EXL R&N
2001 VW Jetta GLS TDI
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  #12  
Old 08-15-2005, 04:09 PM
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No there's no groove. I did this job less than a year ago and I remember clearly.
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  #13  
Old 08-15-2005, 04:10 PM
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I will work on getting some of the Diesel Purge run through the system. Do you think new injectors might help as well? The car really runs out nicely and has quite a bit of power. It does smoke a bit at idle but I think it has always done this. I do notice a hint of idle "miss" when the ELR is set to 3 or higher but it is so slight and I don't think it is an issue. If a copper washer were leaking internally, wouldn't I have a rough idle that was noticeable?
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2006 Honda Odyssey EXL R&N
2001 VW Jetta GLS TDI
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  #14  
Old 08-15-2005, 04:11 PM
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Thanks DieselAddict. Basically, they just sit up there and that's what I remember as well. I have my fingers double-crossed that some purge is going to help. If not, I may have to buy some injectors. I still can't imagine I didn't complete the job properly. I was so careful with everything... torque values, etc...
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2006 Honda Odyssey EXL R&N
2001 VW Jetta GLS TDI
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  #15  
Old 08-15-2005, 04:13 PM
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Good news is.. I have no leaks externally now. I was worried when I noticed I had almost 2" of diesel standing in the plastic pan below. This prompted me to take on this job... The car idled and sounded sooo perfect before and it just baffles me... Well, I'm off to find some diesel purge..

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2001 VW Jetta GLS TDI
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