Don't forget the anti-seize on the glow plugs.

__________________
01 Ford Excursion Powerstroke
99 E300 Turbodiesel
91 Vette with 383 motor
05 Polaris Sportsman 800 EFI
06 Polaris Sportsman 500 EFI
03 SeaDoo GTX SC Red
03 SeaDoo GTX SC Yellow
04 Tailgator 21 ft Toy Hauler
11 Harley Davidson 883 SuperLow

Unless you are leaking at the delivery valves from the copper crush washers, I wouldn't recommend touching them. You've probably read another forum member potentially damaging his IP by replacing them. Wishing him the best and that the IP isn't toast, but let us learn form others mistakes. If it ain't broke I wouldn't fix it. You said it yourself, you'll prolly get in trouble doing some PM.

BTW my 606 has what looks to be the exact same leaking and I think I'll replace that lift pump gasket as a start. Not enough of a leak to cause a puddle though.

I've ordered the parts to do all the O rings in viton, the delivery valves, the fuel pump and I also decided to get all new fuel lines too even though mine are less than two years old. I figured for another forty bucks, I may as well do them too while everything was accessible. I've got a week to decide whether to do it all now or hang onto the parts until needed. Same with R&R'ing the glow plugs. I'm leaning to just doing it all now.

__________________
Len
'59 220S Cabriolet-SOLD and living happily in Malta
'83 240D 351,500 miles original owner-SOLD
'88 560SL 41,000 miles - totaled and parted out
https://sites.google.com/site/mercedesstuff/home
'99 E300 turbo 227,500 miles
'03 SLK320 40,000 miles - gave to my daughter
'14 Smart electric coupe 28,500 miles
'14 Smart electric cabriolet 28,500 miles
'15 Smart electric coupe 28,000 miles

Seems like now would be a great time to spray something on the glow plugs. Some kind of penetrating oil maybe?

Does the 606 have soft return lines like the 603 and earlier engines? I have those also...

The DV, tank screen, fuel filter, and pre-filter o-rings went out today.

-Jim

__________________
1995 S350D, Green with black leather interior.
Bought January 2008 w/ 233,xxx miles.
I did 22,000 miles during the first year of ownership.

Thanks Jim - have hit the glow plugs twice in the last three days with penetrant in anticipation of removing them. I'm hoping that by tomorrow they will have unscrewed themselves.

Yes, there are soft return lines, but they are very dry right now and if they do leak at some point, they can easily be replaced with the manifold in place.

__________________
Len
'59 220S Cabriolet-SOLD and living happily in Malta
'83 240D 351,500 miles original owner-SOLD
'88 560SL 41,000 miles - totaled and parted out
https://sites.google.com/site/mercedesstuff/home
'99 E300 turbo 227,500 miles
'03 SLK320 40,000 miles - gave to my daughter
'14 Smart electric coupe 28,500 miles
'14 Smart electric cabriolet 28,500 miles
'15 Smart electric coupe 28,000 miles

I'm still pretty new to diesels (but I'm ASE certified), so I'm mostly 'listening'.

There are 2 MY99 W210 E300's in my neighborhood, and I'm one of them. The other did have it's injection pump replaced (by the dealer) as a solution for terminal fuel leaks. It was a big bill, and I don't think they knew all their options.

I wish you luck finding the leak... if there is anything I can look at on my car for compare purposes, I will. Wholesale injection pump replacement is not a cost effective solution.

You hit the nail(s) on the head(s) there!

The dealer is quite happy to sell you a complete IP replacement if you don't know that you can just replace a few o-rings. Even when they do offer o-ring replacement, they put buna o-rings right back in there.

-Jim

__________________
1995 S350D, Green with black leather interior.
Bought January 2008 w/ 233,xxx miles.
I did 22,000 miles during the first year of ownership.

OK, they are all in now. I am adding them to the store as we speak. The three new ones you need will only be listed for a little while. After you have purchased them I will only list the complete kit. The page is confusing enough as it is. I need to read up on the software and figure out a better way to lay it all out.

-Jim

__________________
1995 S350D, Green with black leather interior.
Bought January 2008 w/ 233,xxx miles.
I did 22,000 miles during the first year of ownership.

I have simmilar situation and I ended up replacing the entire Fuel Shut off solenoid. It was leaking from the rear O ring. Pul it out and put some fuel inside and see if it leaks. Mine was dripping right away.
I believe that we can change the Solenoid O rings. Have anyone done this?

As usual, does anyone have the size?

-Jim

__________________
1995 S350D, Green with black leather interior.
Bought January 2008 w/ 233,xxx miles.
I did 22,000 miles during the first year of ownership.

Since this is the conclusion (I hope) to this thread that I started, I'll post my results here. Finished replacing all of the O rings with viton yesterday. Also replaced all the fuel lines and replaced the MBUSA supplied O rings with viton, although now that I think about it, I guess it would have been cheaper to just reuse the old fuel lines and replace just the O rings. Oh well, they sure look nice, all white and clear. I also did the delivery valve O rings. First time I did that job and I was a little apprehensive, but with the tips received here, I was able to get through it okay.

It turns out my leak has stopped or at least it didn't leak overnight last night like it had been before. The leak was not at the fuel pump as I at first thought. Rather I'm pretty sure it was leaking from the fuel hose that connects at the rear of the injection pump via a banjo bolt and two copper washers. See attached photo. The O ring on the banjo bolt had a small nick in it where I think it must have been leaking. When I was looking for the leak source, I really couldn't see back there. It makes sense now as a leak there would show up as a wet injection pump and fuel pump bottom. Wherever the leak was, it now seems to be gone.

Had tough time priming the car. Ran down my battery. Added a second battery and it finally fired up. I let it run for about ten minutes with the manifold off. Threw a check engine light, but I'll clear that today. Before I reinstall the manifold, I'll start it briefly one more time just to make sure it still starts.

Overall, not a bad job at all. I chose not to mess with the glow plugs at this time.

Attached Thumbnails

 

__________________
Len
'59 220S Cabriolet-SOLD and living happily in Malta
'83 240D 351,500 miles original owner-SOLD
'88 560SL 41,000 miles - totaled and parted out
https://sites.google.com/site/mercedesstuff/home
'99 E300 turbo 227,500 miles
'03 SLK320 40,000 miles - gave to my daughter
'14 Smart electric coupe 28,500 miles
'14 Smart electric cabriolet 28,500 miles
'15 Smart electric coupe 28,000 miles

Do you recall what size was the o-ring for the back of the IP, banjo bolt. I ordered some of the Viton o-rings as I will replace mine as well, (hopefully this week).

I've noticed air in my fuel lines as well while revving the engine up slightly and a little shaking in the steering wheel. Hopefully these Viton o-rings will cure my issue(s) as well.

I am doing the very same job just now.

Don't you find one fuel hose is badly rubbing against the "wire holder" (my yellow arrow on the attached picture)?

This is a new part #.

Old hose was # 605 070 0632

Replacement new hose # 605 070 1532

The old one didn't have the last bend near the top of the filter head...

I'm going to the dealer tomorrow, I don't want to reinstall the new one like this, it's rubbing so badly it will wear in a couple months I'm sure and start leaking again...

I'm including a picture comparing both fuel lines also.

Attached Thumbnails

   

__________________
BigBen

'98 E300 Turbodiesel 244 000km
RIP '92 300D 2,5 Turbo 632 859,4km due to engine failure

The size of that O ring on the banjo bolt is the same as most of the others for the fuel lines, 2.5 x 8 mm. If you bought the kit from Jim, it's included.

My new fuel hose was the 15 32 version. It is touching the wire holder, but I'm not too terribly concerned about it.

__________________
Len
'59 220S Cabriolet-SOLD and living happily in Malta
'83 240D 351,500 miles original owner-SOLD
'88 560SL 41,000 miles - totaled and parted out
https://sites.google.com/site/mercedesstuff/home
'99 E300 turbo 227,500 miles
'03 SLK320 40,000 miles - gave to my daughter
'14 Smart electric coupe 28,500 miles
'14 Smart electric cabriolet 28,500 miles
'15 Smart electric coupe 28,000 miles

If I have no other choice, I'll put the new one on and add some extra protective covering on the hose, like a piece of splitted rubber hose attached with tie-wraps.

I still don't get why it was replaced, the original design was just fine.

Bye,

__________________
BigBen

'98 E300 Turbodiesel 244 000km
RIP '92 300D 2,5 Turbo 632 859,4km due to engine failure