OM606: New delivery valve O-rings

[scott19_68]

Well, I was up until midnight finishing my delivery valve but it was well worth it! Drove to work this morning and not a drop of fuel anywhere on the IP. I did not realize how much power that had been lost since the leak started, but it is back!

No pictures to post since it's been covered here before by several people but I do have some notes:

- The only way to get the bolt that holds the intake manifold & EGR body to the air supply from the intercooler is from underneath the car. Put the car up on the ramps and pull the middle belly pan plastic thing to access - I dropped stuff down there at least a dozen times. Also, when the job is done and you are ready to crank the starter to purge the air, the elevated front end REALLY helps minimize the process. Crank for 15 seconds, wait 1 minute, crank for 15 seconds more and it should start right up!

- If you have never had your intake manifold off, prepare yourself for what looks like the inside of a chimney after 20 years of use. The black gunk is everywhere especially caked around the EGR (obviously). I routinely run up the RPMs to 5k every night when arriving home from work so I am guessing the PO did not. Soaking the manifold/EGR in diesel fuel just makes black diesel fuel - I think a steam cleaner or biodiesel may be the only way. I made more of a mess than anything - I actually had to scrape about 1/16" of gunk from inside the EGR body. I think I will pull the head at around 160k mi and change the glow plugs and gasket and give it a good cleaning.