This is a 1993 W124 300d and I am pretty sure that the source of this leak is the manual stop lever.

The lever has a lot of play to and fro as well.

Is there a way to fix this without replacing the whole IP?

Also, from the pics can any of you ascertain if there is an additional leak elsewhere?

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1993 W124 300D
-297K on the clock as I type this.

After I posted this thread I cleaned the areas in the photos.

I will be checking the area as I drive this week to see what's what.

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1993 W124 300D
-297K on the clock as I type this.

Common problem. Easy fix. Remove the nut and special screw that hold on the lever. Remove the lever. Remove the e-clip on the shaft. Slide off the washer. Remove the hardened and shrunken o-ring behind the washer that is causing the leak. Replace it with the o-ring that comes with either the fuel filter or oil filter (I can't remember which). Reinstall everything in reverse order. Leak fixed!

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1987 W201 190D

I thought it was the o-ring that goes on the shaft through the oil filter, which doesn't come with the oil filters I buy.

I don't think that much of a leak is coming from the shutoff lever shaft. I'd say the o-ring for the shutoff actuator is at least contributing, and possibly the o-ring for the control rod sensor as well. You can't replace the o-ring for the control rod sensor without taking the IP apart but you can probably get it considerably cleaner by replacing the other o-rings. IIRC OE shutoff actuators have metal canisters so that plastic canister suggests a non-OE replacement.

Sixto
87 300D

If the O-ring is the same size as the 2 at the bottom of the 617.9 type Engine Oil Filter Stem the size is 6mm x 10mm.

If you buy an O-ring kit from Autozone for about $7 you will get 24 of the above size along with a bunch of other sizes (good for a lot of filter changes).

Attached Thumbnails

 

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84 300D, 82 Volvo 244Gl Diesel

OK, I didn't read the directions well enough and proceeded to also take off the large nut around the shaft.

The shaft moves around a bit and has a plastic sleeve on it inside the pump body.

When I put it together it looks like the shaft is not in the exact same place it was when I removed the large bolt.

Have I screwed something up?

The stop lever is slightly higher than it should be in the current configuration.

And, for the record, it's the smaller o-ring that comes with the fuel filter that fits perfectly.

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1993 W124 300D
-297K on the clock as I type this.

OK, I did mess something up by loosening the big nut at the base of the shaft.

Now the car will not turn off with the key and the stop lever doesn't even move when I turn off the ignition.

I can turn the car off by pushing down on the stop lever but I have to push down much harder than I used to.

Did I cause serious damage or is this fixable without removing the shutoff actuator?

I tried to remove it but the back bolt is damn near impossible to reach. I think you may actually have to remove the intake manifold to do it. I also cracked it when I replaced the one bolt I did get off of it.

(UPDATE: I fiddled with it enough that everything now works according to design)

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1993 W124 300D
-297K on the clock as I type this.

Unfortunately, I have found the source of my IP leak.

It looks like it's the rearward-most injector line.

It looks like it is leaking from the fitting that connects the line to the body of the IP.

I suspect that this is a big deal.

I tightened the collar looking things but I then noticed that they are probably just to keep the starburst looking nuts from turning.

There was actually diesel pooling up on the IP below the part where the lines attach.

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1993 W124 300D
-297K on the clock as I type this.

Can you tell if it's leaking from the nut at the end of the injector line or from below that junction? You either need a new injector line or a deliver valve seal. Tedious work but not difficult.

Sixto
87 300D

I'm pretty sure that it's leaking from below that junction.

Everything above the "starburst" nut looks dry.

I suspect that it's only one that's leaking but I can't be sure.

I suspect it's the delivery valve seal.

Is there a write-up on this?

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1993 W124 300D
-297K on the clock as I type this.

Different engine, similar IP -

http://www.peachparts.com/Wikka/OM606DeliveryValveSeals

I'd clean the IP before exposing the delivery valve innards

Sixto
87 300D

Thanks for the link.

I agree.

That guy could have cleaned up a bit before he exposed the innards of the very expensive IP.

All that debris lying around those openings made me very nervous and it wasn't even my car.

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1993 W124 300D
-297K on the clock as I type this.