606 leaking diesel again - Page 2 - PeachParts Mercedes-Benz Forum

sokoloff · #16 05-04-2007, 02:29 PM

I've already sprayed it down. It leaked all the way down enough to wet the oil pan just sitting in the garage overnight, so I'm hoping that cleaning it up will show me where the leak is originating.

Tell me more about the delivery valve O ring job. I'll do a search as soon as I send this, but is this the job where there were questions about the torquing procedure, i.e. 30nm, then back it off and then eventually torque to 35nm? Any special tools needed?

TMAllison · #17 05-04-2007, 02:35 PM

Thats the one. Some question currently as to which torque procedure is correct. 30, 30 & 35NM or 35Nm one time only. I did the latter.

You need the special splined MB socket and DO NOT want to distrub the valve itself. The only parts being removed and reinstalled from inside are the spring and crush washer. Everything else doesn't get touched or moved as thier factory orientation is critical.

F18 · #18 05-04-2007, 03:16 PM

I agree with Terry!.....One time torque of 35NM (~26ft lbs) worked just fine.
The job is pretty straight forward when you have the manifold off. I give it a 2 out of 10 for difficulty......I think it would be a mistake not to do it now with everything out of the way.....believe me I was short sighted the first time I chased leaks on mine and wished I had changed all 6 Delivery Valve O Rings instead of just the ones that leaked .

But there was NO ULSD fuel in use at the time!

sokoloff · #19 05-04-2007, 03:51 PM

Okay, please help me out and make sure I'm getting everything I need. I really hate to place an order and then find out I left something out once I undertake the job.

From Jim's webpage, http://www.fryerpower.com/store/page11.html, the $10 combo viton O ring pack. I'll also probably pick up a couple of pre-filter O rings while I'm at it.

From my favorite parts supplier(s) -
6 delivery valve springs, 000 017 19 17, at $4.13
2 fuel line clips, 601 078 26 41, at $1.13
7 fuel line clips, 603 078 01 41, at $1.13
Special socket, 617 589 01 09 00, at $19.88

I have seven of the rubber pads on hand that go under the fuel line clips as well as a new manifold gasket.

I can't find the correct part number for the copper seals in the delivery valves. The EPC list about fifteen different numbers. What is the correct number?

Am I missing anything or are there any other "while I'm already in the area" parts I ought to order?

Thanks.

TMAllison · #20 05-04-2007, 04:18 PM

This is what Phil came up with for my 99 E300 (OM606.962) when I did mine.

0049974540 Delivery Valve Washer $.90ea

Dont know if it's MB's number or his....get 8 of em in case you drop one or two. Cheap insurance so you can finish the job.

Jadavis · #21 05-04-2007, 04:18 PM

I just checked the fuel filter part numbers for my 1987 and your 1999 MB's. They are the same, so the fuel filter o-rings will be fine. We already knew the DV o-rings are the same.

I've ordered viton o-rings for:
Shutoff valve 2.5mm x 12mm ID
Fuel line 2.5mm x 8mm ID (1 located at fuel filter housing)
Fuel line @ filter housing 2.5mm x 10mm ID

I'll list them on the site soon. Go ahead and order what you need. They fit neatly into a regular envelope and won't cost much to ship separately...

.

If you order the combo really soon I can drop at the post office into today's mail.

-Jim

Jadavis · #22 05-04-2007, 04:49 PM

OK, I added the whole kit at the bottom of the page.

http://www.fryerpower.com/store/page11.html

I'll ship what I have right away and ship the rest once it comes in.

The 2.5mm x 8mm where twice the price of the others. Of course those are the ones that there are the most of.

-Jim

sokoloff · #23 05-04-2007, 06:11 PM

Thanks Terry and Jim.

Terry - 0049974540 is the Mercedes number - thank you.

Jim - thanks for the offer, but I didn't get my act together enough to send you an order today. Not a big deal, since the other parts won't be here until next week sometime anyway.

Maybe this thread and all the part numbers will help someone else in the future.

sokoloff · #24 05-04-2007, 06:18 PM

Something else that crossed my mind during this leak situation. I think I see now why Mercedes is providing that cover for the replacement driver's side motor mount. I did use it on mine and am glad I did. I would suppose that letting the rubber mount marinate in diesel fuel for very long will significantly shorten its life.

sokoloff · #25 05-06-2007, 02:25 PM

This leak has got me stumped. After cleaning everything off, I checked on things again today and it is leaking enough that there is a small puddle of fuel on the garage floor after two days. Everything above the fuel pump looks to be dry including the fuel shut off valve. The highest wet areas are under the fuel pump and under the injection pump. Since I did most of my cleaning and spraying from above the other day, I sprayed everything clean again, this time also spraying and wiping it from underneath. I'll check for wetness again tonight or tomorrow. See attached photos.

I did a quick search and didn't come up with any major problems with the 606 fuel pump leaking, but I guess it could. Has anyone had a problem with it and what all should be replaced if it is in fact the problem? There is a gasket where it mates to the injector pump and inside there are the following parts, a valve spring, a valve and three sealing rings. Is there anything in there that I should absolutely not touch as is the case with the delivery valve R&R? Should I use viton sealing rings for the sealing rings in the fuel pump that should be replaced? Anyone have the sizes so Jim can obtain them? I can provide the part numbers if necessary.

Bio300TDTdriver · #26 05-06-2007, 10:08 PM

Quote:

Originally Posted by Jadavis

I just checked the fuel filter part numbers for my 1987 and your 1999 MB's. They are the same, so the fuel filter o-rings will be fine. We already knew the DV o-rings are the same.

I've ordered viton o-rings for:
Shutoff valve 2.5mm x 12mm ID
Fuel line 2.5mm x 8mm ID (1 located at fuel filter housing)
Fuel line @ filter housing 2.5mm x 10mm ID

I'll list them on the site soon. Go ahead and order what you need. They fit neatly into a regular envelope and won't cost much to ship separately...

.

If you order the combo really soon I can drop at the post office into today's mail.

-Jim

Jim, I got the other kit from you I think I'm going to need the three new ones too. Will you post to this thread when you get them in?

Chris

TMAllison · #27 05-06-2007, 10:27 PM

The fuel/lift pump does have a gasket which you know already. You also know that the pump is not a high fail part; I can't remember anyone replacing or fiddling with one since I've been around the forum.

I would run it a bit now that it is clean and then reach under the manifold and feel around the two fuel lines plugged into it and see if that isn't where the leak is coming from.

Jadavis · #28 05-06-2007, 10:44 PM

Quote:

Originally Posted by Bio300TDTdriver

...I'm going to need the three new ones too. Will you post to this thread when you get them in?

Chris

Will do.

-Jim

deanot442 · #29 05-07-2007, 12:28 AM

I have had a less than positive experience when spraying chemicals like brake cleaner and carb cleaner on or near o-rings, it tends to significantly shorten their life. (it causes shrinkage and drying.)
I might also look at the fuel heater (just before the pump) o-rings and the return line to the filter at the filter mounting block. I saw that your return lines looked dry, but did not see any photos of the filter assembly. I have experienced leaks from both of those places on my OM603 ( slightly different but worth a closer look)

sokoloff · #30 05-07-2007, 08:53 AM

Terry/Dean/others - the fourth picture in my first post shows the filter area. They are bone dry. I gave things a quick look this morning and once again everything is bone dry until I get to the underside of the fuel pump. The two fuel lines going into the fuel pump on top are bone dry too. Also the underside of the injection pump housing is wet again and there is enough of a leak that diesel fuel has wet the side of the block down to the oil pan. I'll crawl under it in a couple of hours to verify all of this. It seems like the only place the leak can be coming from is the fuel pump. Since there are only three openings it in and the two for the fuel lines are dry, it's got to be that gasket where it mates to the injection pump.

So my plan is to change that gasket on the fuel pump and that hopefully will fix my leak. But, since I'm already into this and everything is exposed, I'm going to do some preventive maintenance work which often gets me into trouble. I'm going to order the 606 viton O ring kit from Jim and just change out every O ring everywhere. I just did the fuel hoses about a year and a half ago, so they should still be fine. It's not that difficult or expensive of a job. I'll also get new copper washers and replace all of them too. I will also buy the O rings, valve and valve spring that are inside of the fuel pump. If someone has experience or warnings about replacing/rebuilding the fuel pump, please speak up. Also, if someone knows the correct size of those fuel pump O rings, let me know, so I can see if Jim has them.

Comments, warnings, suggestions appreciated.