Here's a list of part numbers for seals when your 603.96 IP turns into a sieve:

004 997 46 40 = bottom cover seal
001 074 37 80 = side cover seal (aluminum cover, different seal for steel cover)
000 091 17 80 = lift pump seal
010 997 56 48 = shut off actuator seal
001 074 43 80 = rear cover seal
013 997 81 48 = ELR actuator seal
013 997 09 47 = input shaft seal (who would know this is leaking???)
012 997 83 48 = front seal
123 304 00 60 = VCV seal
N 007603 018100 = RIV plug crush washer (I think, diagram's not clear)

I didn't see a part number for the control rod sensor connector which is just as well since the IP has to come apart to replace that seal... and each one I've seen leaks!

I didn't see a part number for the shut off lever shaft seal.

Crush washers for fuel supply and return lines:

N 007603 012405

Crush washers for lift pump line:

N 007603 010100

While the IP's out, good time to replace the thermostat o-ring:

011 997 39 48

gsxr has a Bosch parts list with some of these seals - http://www.w124performance.com/images/OM603_injection/Bosch_IP_parts_list2.doc There's a parts diagram I can't make sense of due to poor resolution.

Sixto
87 300D

Are you tackling this project on your 603? I'm currently investigating Coda's options since her IP is leaking.

__________________
daw_two
Germantown, TN

Links:
Sold last car --- 05/2012 1984 300D Light Ivory, Red interior
No longer selling Cluster Needles Paint
No longer selling New Old Stock (NOS) parts

Past:
3/2008 1986 300SDL "Coda"
04/2010 1965 190D(c) "Ben"
& many more

I've done this before. If you can remove, install and time the IP there's nothing to replacing seals. I didn't do the VCV seal or input shaft seal. Current car has a leaking bottom seal...

Sixto
87 300D

I've never set the timing and the guys I called just made it sound too easy (for them to do). In addition, I found their "re-seal" rate to be reasonable.

__________________
daw_two
Germantown, TN

Links:
Sold last car --- 05/2012 1984 300D Light Ivory, Red interior
No longer selling Cluster Needles Paint
No longer selling New Old Stock (NOS) parts

Past:
3/2008 1986 300SDL "Coda"
04/2010 1965 190D(c) "Ben"
& many more

How much? I'm guessing it's a solid 3 hours of work. There's no end of while-you're-in-theres if you do it yourself so plan on a weekend.

Sixto
87 300D

How about torque specs for tightening the gaskets, ideas?

Also, gasket sealent needed?
Any pointers?

__________________
1987 300SDL "Rudolf" 239k 8/10


Gone but not forgotten
-1980 F250 4X4 351C Snowplow "The Beast"
-1976 Caddy Eldo Convertible, in triple red. "Red headed Slut"
-2002 Honda Accord EX-V6 loaded 107k, My first brand new car!


*IM A HORRIBLE SPELLER*

BUMP

__________________
1987 300SDL "Rudolf" 239k 8/10


Gone but not forgotten
-1980 F250 4X4 351C Snowplow "The Beast"
-1976 Caddy Eldo Convertible, in triple red. "Red headed Slut"
-2002 Honda Accord EX-V6 loaded 107k, My first brand new car!


*IM A HORRIBLE SPELLER*

I don't have any torque specs. Screwdriver tight should do it. Coat o-rings with engine oil. Otherwise no sealant, just dry gaskets on clean and dry surfaces.

Sixto
87 300D

i have not been able to find a part number or dimensions for the stop lever shaft seal,both mine and my sons are leaking and the dealers parts book does not show the seal or the lever and i dont see either on GSXRs drawing either. Any help would really be apreciated.
Don

__________________
Red Green "This is only temporary,Unless it works!"

97 E300D 157000 miles
87 300TD ?141k? miles

I used a generic o-ring for the shut off lever shaft. Someone said an oil filter post o-ring fits perfectly.

Sixto
87 300D

input shaft seal... right or wrong way to face it for installation? the old once was in pieces (hmmm the source of the leak in that area?) so i couldnt tell the orientation. Also, whats the proper procedure for installing the input shaft seal? i think mine went in a tad cockeyed

also i was "pleasently" surprized my the pint or quart of oil i got all over myself and bench and tools while dissassemblying.... do i need to refill the ip somehow or will that be done upon startup?

also... when i locked and removed the pump my engine timing is about 17-18 degrees (that is where the slot lined up the best. is this ok of do i need to borrow the RIV tool?

__________________
1987 300SDL "Rudolf" 239k 8/10


Gone but not forgotten
-1980 F250 4X4 351C Snowplow "The Beast"
-1976 Caddy Eldo Convertible, in triple red. "Red headed Slut"
-2002 Honda Accord EX-V6 loaded 107k, My first brand new car!


*IM A HORRIBLE SPELLER*

I didn't touch that so I can't help you there. If the input shaft seal is leaking, it would leak into the timing chain cavity, not outside the engine. An external leak, such as down the side of the block towards the engine mount arm is more likely a bad o-ring between the IP and block.

I don't remember what the FSM says about this. I would fill as much as possible through the RIV port as you would a differential. Fill it on the bench with the port facing up then set the IP to vertical to let excess oil drip out the port before installing the locking tool for installation.

The A-B light makes quick work of setting IP timing but you can get decent results by hand. Get everything back in place and start the engine to ensure everything's at least as good as it was prior to pulling the IP. Then worry about IP timing. In fact if IP timing is that far off, check chain elongation by either eyeballing the cam sprocket alignment mark or the FSM method of dial gauge on the cam lobe. No sense setting IP timing on a chain that's out of spec.

Sixto
87 300D

As always thanks you for the insight.

what about the ringfor the ELR... i removed the 3 holddowns @ 3 & 9 oclock but i cant wiggle it out am i missing something here?

__________________
1987 300SDL "Rudolf" 239k 8/10


Gone but not forgotten
-1980 F250 4X4 351C Snowplow "The Beast"
-1976 Caddy Eldo Convertible, in triple red. "Red headed Slut"
-2002 Honda Accord EX-V6 loaded 107k, My first brand new car!


*IM A HORRIBLE SPELLER*

oh, how do i remove the elr? i took the 2 screw/holddowns off that are ar 3 &9 o'clock but it wont wiggle out

__________________
1987 300SDL "Rudolf" 239k 8/10


Gone but not forgotten
-1980 F250 4X4 351C Snowplow "The Beast"
-1976 Caddy Eldo Convertible, in triple red. "Red headed Slut"
-2002 Honda Accord EX-V6 loaded 107k, My first brand new car!


*IM A HORRIBLE SPELLER*

Thanks Sixto, its a keeper, I emailed it to myself for storage.

Thanks
Harry