I have developed a fuel leak. It appears to be comming from the plastic fuel lines or o-rings. However, there is fuel leaking from the black plastic object (I believe its the fuel shutoff valve). Would the fuel leak from the shutoff valve or is it most likely comming from the fuel lines connected to it or the o-rings. Also, I ordered a intake gasket to remove the intake but the web site did not clearly indicate the gasket was for a diesel. What is the MB part number for the correct intake gasket. Any help is appreciated.

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1982 300d Turbo Diesel (Sat in P/O's Garage for 10 years) Purrs Like a Kitten

1999 E300 Turbo Diesel

1998 SLK 230

Do a search, sit back and enjoy. There are tons of stuff on fuel leaks on that engine. Your best bet is likely to just replace every fuel line and O ring (use Viton) while the manifold is off.

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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

When lines leak at the ends, it's probably only the little O-rings that are bad. This was the case on my '99 E 300. Save a hundred bucks or so; don't replace the whole line. Steve

I have been there. I recommend that if you pull the intake replace all of the lines and o-rings. Also, go to mcmaster-carr.com and purchase Viton o-rings. They will last much longer. Here are the o-ring sizes:
Hose seals
O-ring
13mm OD
8mm ID
2.5mm thick

Shut-off Valve seal
O-ring
17mm OD
12mm ID
2.5mm thick

Good Luck

Depending upon the cleanliness of everything you may need to spray it with cleaner. Once its clean you can run it a bit and then feel each connection and find the wet one. The shutoff valve oftentimes appears to be the culprit as it is down low and gets dripped on. The SOV does have an oring seal behind it that leaks too.

If the IM is going to come off just do all of them and be done with it for 5 more years. Get a new EGR seal ring too.

You can purchase new fuel lines from MB for ~$60 or repalce the orings only. The white horseshoe are pushed closed to spread and release the clips that snap the fuel lines in place. New lines are clear, if yours are yellowed it is sometimes nice to replace the entire line so that in the future you can see if you have any bubbles present.

IM bolts are torqued to 20NM from center outward. You'll need 6 point star bits.

Here are the oring sizes (see post #2): OM606.962 o-ring size

JADAVIS (forum member) sells an o-ring kit for our cars using viton orings on his website: fryerpower.com

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Terry Allison
N. Calif. & Boca Chica, Panama

09' E320 Bluetec 77k (USA)
09' Hyundai Santa Fe Diesel 48k (S.A.)