Bump for customer.

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John HAUL AWAY, OR CRUSHED CARS!!! HELP ME keep the cars out of the crusher! A/C Thread
"as I ride with my a/c on... I have fond memories of sweaty oily saturdays and spewing R12 into the air. THANKS for all you do!

My drivers:
1987 190D 2.5Turbo
1987 190D 2.5Turbo
1987 190D 2.5-5SPEED!!!

1987 300TD
1987 300TD
1994GMC 2500 6.5Turbo truck... I had to put the ladder somewhere!

this thread is so incredibly well done, thanks.

I had a code for the glow plug controller bad, tested glow plugs for resistance only, one was bad and two questionable. Controller code has not reappeared so must have just been faulty glow plugs. I did the delivery valves, glow plugs and injectors while it was open. I have also had a sharper knock than normal diesel clatter that online writers said could possibly be delivery valve.

I thought I would share a few snags I ran into that took me a while to figure out.

1999 E300 165k

The easiest way to get to the lower intake bolt is from underneath.

I wanted to make sure no leaks before put the manifold back on. What took me the longest was getting it started. (all rags were out) I cranked a little and where I saw fuel on the loose fuel line at the injector I tightened the fuel line. I saw fuel at 1,2,5,6 so these line were tightened but no fuel at 3,4 after about a minute of combined cranking time. I’m starting to think I put something back together wrong or possibly the IP was weak. Long story short, with ¼ tank of fuel, incline in front of garage and front up on ramps - No Fuel. Pushed off ramps, jacked up rear fuel and started right up. The initial fuel I saw must have been residual. Rookie mistake.

The car smoked for a while after I put it all back together. I cleaned the intake manifold with diesel and transmission fluid, I think this combination works better than engine degreaser for that thick gunk. Drove it fairly hard for 10 min and cleared up.

I had 2 new injectors in case any were bad when I tested them. I had a homemade pop tester from the 126’s I’ve had and it worked fine. I tested all the injectors and all had poor spray patterns to varying degrees and all popped about same pressure (1950 psi). I cleaned the tips - pattern still poor. I could only get 4 apart to clean needle and nozzle, greatly improved spray pattern. I used a brass brush and a wood tooth pick.

Glow plugs were straight forward except #6, sprayed, soak, turn, repeated numerous times. Finally counted threads, 8, but not coming out. Used a trim removal tool to pry while I turned the glow plug with a wrench, finally working the plug out. Gunk on shaft not carbon on tip. Reamed with a homemade reamer from an old glow plug and that opened them up pretty good. Thought about using anti-seize on shaft but didn’t.

I anyone other than me ever drops a tool, take both lower pans off so things drop straight thru to the ground. Write up longer than I planned but hopefully it helps someone.

Thank You to the DIY’ers that do such a thorough job of step by step instructions and the other contributors who have snags you won’t find in a repair manual for trouble shooting.

I just finished doing the delivery valves and new plastic lines and fuel supply hose. I think it's more difficult on the non-turbo models, much more crowded on that side of the engine. It could also be Parrot of Doom's car is right hand drive. Anyway, my back and hands are SORE!

These fuels leaks have been nagging me for a while, feels great to have them all sorted out.

Thanks for great write up.

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this is a great write up on redoing the injector pump.
my "Stealer" says I have an air leak in the fuel pump but I think this is actually in the pump that moves the fuel form the tank to the filters as I see air in the clear lines to the filters.
someone told me this first pump is attached to the injector pump and can be purchased seperately. does anyone know of a post just to replace the initial fuel pump.
thanks

HAPPY NEW YEAR TO ALL.........Very informative, pictures are excellent. A BIG THANKS to you. Just started my 1997 W210 E300 today. However having two problems first fuel is coming out of the deliver valve like mad now that I have number 6 removed. Big tray to catch it of course on ground...The second issue which is of concern is that the crush washer is stuck way inside on the lip of the delivery valve and I cant seem to get it out. Really concerned about scratching the inside of the valve to get it out. Going to make a small pick from a fish hook to try and get it out. By the way the rate at which fuel is flowing makes me wonder how I am going to get the spring to stay in place to put it back together.

Rod

Clamp off the fuel supply line where it connects to the hard line on the drivers side firewall.

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-Evan


Benz Fleet:
1968 UNIMOG 404.114
1998 E300
2008 E63


Non-Benz Fleet:
1992 Aerostar
1993 MR2
2000 F250

Evan I actually though about it after I finished all 6 delivery valves and collected over a gallon of diesel on the ground...LOL. If I have to go back in that's definately the way to go. By the way I am still putting back the manifold etc. so have not started the engine. ... In order to help centre the spring. I placed the spring in the delivery valve with the little round assembly and the crush washer, I was then able to slip the entire assembly into the body of the injection pump by putting it into the hole sideways then standing it upright...seemed to work fine for me but only time will tell...

Rod

Rod, How did that work out for you to assemble things in the valve? I understood that leaving "the little round thing" alone was very important..?
Did you just buy the tool? Had this job done at an indie place about 50K ago, a little surprised they're leaking so soon.. Matt

Did the indie use OE seals or aftermarket? And are you using pump diesel, or biodiesel?

Not sure on the seals he used, think he got them from the dealer.. As I was loosening the delivery valves, 4, 5, and 6, were very tight and 1, 2, and three were fairly easy... not too happy about that!!

FML!

Today, just a few minutes ago in fact, I was finishing this delivery valve seal job. I Noticed when loosening the DV they were all TIGHT. Torque wrench read as much as 120fts on some of them. Other's were in the 80s.

I was tightening them to about 25 foot pounds.. and the last one... BROKE... it's snapped in half, part of the delivery valve threads still in the I.P.

I could cry... lol.. really though.. it's like a kick in the nards... I guess the overtightening (probably done by the pervious owners mechanic) weakened the Delivery valve? I noticed when removing the DV spline holders they were put in wrong. Does anyone have an idea where I could find a replacement delivery valve for an om606? GOD knows I'm praying with my fingers crossed. I gotta find out how I'm going to get the rest of the DV valve out

Dealer, Bosch Service Center, junk yard. A 603.9xx DV holder is likely the same. Part numbers would confirm.

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Terry Allison
N. Calif. & Boca Chica, Panama

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

Thanks!

I could kick myself. I had a 603 delivery pump sitting in my garage for years.. i just got rid of it a few months ago. I hate murphy's law!

I talked to a friend who runs a mercedes shop. he's going to try and source one from his friend who rebuilds the pumps. He said he wasn't surprised it snapped after being torqued that much.

I am still surprised that they had that much torque on them. I mean, I'm surprised it didn't crack the pump or something.

This isn't the first F up I've found from the previous owners mechanic. In fact I can almost guarantee if i go through the service records I'll find a work order where they describe leaking and them retightening the delivery valves. Hopefully this will be the last problem. I've had the car 4 years and it's been a great vehicle.

I already got the piece that was stuck inside the pump out.

Bump this thread for myself.

Thanks Parrot of Doom!

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[SIGPIC] Diesel loving autocrossing grandpa Architect. 08 Dodge 3/4 ton with Cummins & six speed; I have had about 35 benzes. I have a 39 Studebaker Coupe Express pickup in which I have had installed a 617 turbo and a five speed manual.[SIGPIC]

..I also have a 427 Cobra replica with an aluminum chassis.