1999 E300D Injection Pump Failure?!? - Page 2 - PeachParts Mercedes-Benz Forum

chrisf · #16 09-30-2008, 12:35 PM

Thanks Jake but I've got a rental socket on the way from one of the guys here on the forum. It's the last item I need. I got all viton seals from www.fryerpower.com. It was definitely worth the $27 for all the seals to show up in my mailbox. Once the socket shows up I'll start work on the delivery valves. Thanks again everyone.

barry123400 · #17 09-30-2008, 10:21 PM

I would probably only do the #4 injection pump element seal first and run the engine. If all is well I personally might wait for any additional seal failures. This seal changing job does not work out well in every instance and mathamatically you are increasing the chances it might not at a phenominal rate by doing all the seals at once.

On the otherhand you might just change them all and all is well. It seems to be more of a luck of the draw type of problem to me when it occurs rather than a skill issue for some unknown at least to me reason.

Clean your working area really well before removing anything and clean it again. Preclean your socket and the tools that drive it. Dirt or tiny pieces of the old seal may be the not understood villan in those cases that do not work out well.

Unfortunatly the socket is a rental and know that would tend to influence me as well. The other component of the equation is of course when are the other element seals going to go if I leave them? Read through the archives to get a feel for the success rate versus failure on this job. I would tend to base my decision primarily on that.

Also if the number four does not correct it will be clear cut and not possibly overlaid with new issues. The pump is going to have to be serviced or replaced then. Odds are much better than 50-50 it is just the seal though.

Well I just re read your initial posts and guess you have no real option other than to change them all. You are burning vegatable oil.

TMAllison · #18 09-30-2008, 10:32 PM

The OP's been pointed to, and provided with, the appropriate cautions in order to do the job. One DV (or all) shouldn't matter if those cautions are followed. I'd be inclined to do them all so they were all known to have good seals and to be properly torqued.

He should also know the engine can be started and run w/o the IM to see if DV#3 resolved the issue and that any codes that appear can be erased later.

chrisf · #19 10-07-2008, 11:13 AM

I've got the intake manifold off. This is the first time I've done it myself. Much easier than I expected. One thing concerns me. I see a little oil has been leaking from this area (see picture). I'm thinking it leaked from the EGR seal (which I have a Viton replacement for) but I wondered if you guys would suspect anything else. Also, there was a small amount of oil running down the air intake tube before I loosened anything.

I'm about to soak the intake manifold in biodiesel (as I read about on this forum) and wondered if I should remove the EGR before the soak. Should I?

Thanks again for all your great help!

nhdoc · #20 10-07-2008, 11:29 AM

What you have pictured is normal and probably due to some leakage on the big o-ring. If you replace it you'll probably stop it from coming back but even if it does it is nothing to worry about. Remember that the charge pipe is under pressure, not vacuum with up to 15 PSI of boost and it's just not a hermetical seal there so the Exhaust Gases and sooty crud tend to leak out just a little. Mine looks exactly like that.

#21 10-07-2008, 11:34 AM

Yes, remove the EGR body and clean the manifold. Biodiesel getting onto the vacuum diaphragm would not be good for it.

chrisf · #22 10-07-2008, 11:58 AM

Well I just found out what people do when they don't have a spline socket to torque the delivery valves on with. They use a chisel on the keepers!!!! (see pictures)

This ride gets more interesting everyday.

Thanks for the words of assurance on the EGR.

Bajaman · #23 10-07-2008, 12:01 PM

LOL makes getting the proper torque a little difficult using that method.

TMAllison · #24 10-07-2008, 12:23 PM

A more intelligent idiot would have welded a retainer to an old socket and used it as a tool instead.

nhdoc · #25 10-07-2008, 01:04 PM

Quote:

Originally Posted by chrisf

Well I just found out what people do when they don't have a spline socket to torque the delivery valves on with. They use a chisel on the keepers!!!! (see pictures)

This ride gets more interesting everyday.

Thanks for the words of assurance on the EGR.

Another "professional" tech strikes again! You gotta give them credit for ingenuity - I would never have thought of turning them into removal tools!

If yours are as tight as mine were (and I mean I had to use a breaker bar to crack them free) I can only imagine how much hammering it took to get them off with that method...are those metal shavings on the bottom of the IP housing in the first photo?

chrisf · #26 10-07-2008, 01:42 PM

Quote:

Originally Posted by nhdoc

...are those metal shavings on the bottom of the IP housing in the first photo?

No, it is just brake cleaner.

chrisf · #27 10-07-2008, 11:16 PM

I just put it all back together. I cleared the injector lines and it fired right up. After a second or two it settled down to the smoothest idle it has ever had.

Working slowly on the valves was the key. I felt like I was playing a game of grown-up "Operation" getting those crush washers out .

What took the most amount of time for me was putting the intake manifold back on. It took me 45 minutes to get the bolt and clamp back on the EGR. The rest was really easy with your instructions.

You guys saved me lots of money and I really appreciate it.

You guys ROCK!!

barry123400 · #28 10-07-2008, 11:45 PM

Happy to see it all worked out for you. Especially when you consider the care that was taken the last time.

They could as easily have damaged something that would have messed up you effort. If the past owners did not do this how can a working mechanic take such liberties with such an expensive part? Also since it was someone elses property it is beyond me.

notfarnow · #29 10-08-2008, 10:41 PM

Quote:

Originally Posted by chrisf

Well I just found out what people do when they don't have a spline socket to torque the delivery valves on with. They use a chisel on the keepers!!!! (see pictures)

This ride gets more interesting everyday.

I always find it really, really disconcerting when I discover that a PO or his mechanic had hacked on one of my cars. Makes you wonder what else might be amiss.

Quote:

Originally Posted by TMAllison

A more intelligent idiot would have welded a retainer to an old socket and used it as a tool instead.

Sounds like my kind of idiot! Maybe I'll do just that... would a retainer from an earlier (617?) engine be the same diameter and have the same # of splines? I have a couple kicking around.

Aw, who am I kidding... I'll use vice grips and a hammer (kidding, kidding)

Quote:

Originally Posted by chrisf

Thanks for the words of assurance on the EGR.

Mine looked the same, so add my vote.

Quote:

Originally Posted by chrisf

What took the most amount of time for me was putting the intake manifold back on. It took me 45 minutes to get the bolt and clamp back on the EGR.

Ahh! That clamp is a pain! Sure comes off easy though, doesn't it?!

Hey chrisf, I see a worm-gear hose clamp in that pictures. Change that out for a proper fuel injection hose clamp, and make an appropriate sacrifice to the om606 gods. Otherwise they may smite you with a sheared glow plug.

TMAllison · #30 10-09-2008, 12:28 PM

Quote:

Originally Posted by notfarnow

Sounds like my kind of idiot! Maybe I'll do just that... would a retainer from an earlier (617?) engine be the same diameter and have the same # of splines? I have a couple kicking around.

Aw, who am I kidding... I'll use vice grips and a hammer (kidding, kidding)

Jake - You'd need one from any 60x IP. Completely different animal on a 61x engine.