96 E300D, No fuel from #5 and #6

[lindashu]

6 months ago car started shutting off randomly (could be on the freeway at 70 or on the street at 35) as well as the cruise control and was determined to be the K40 relay and would be $300.00 to fix. So I parked it for five months until I could afford the work. While at the shop they tell me I need new IP DV seals and washers and should do the glow plugs. Ok so all that's done, now they say they can't get fuel out of number 5 and 6 nozzles and that I need to have the IP rebuilt to the tune of $1800.00. Does this seem likely? Car has 141,000 miles on it, has had impeccable maintenance (with exception to past 6 mo.) and started and ran just fine (just shut off when it felt like it). Could the pump just go to hell in a hand basket while sitting in the driveway? If this is so, can anyone recommend a reliable Bosch service dealer with better price to rebuild or can anybody tell me if they know anything about Santa Rosa Diesel. Thanks!

[Aquaticedge]

Originally Posted by lindashu

6 months ago car started shutting off randomly (could be on the freeway at 70 or on the street at 35) as well as the cruise control and was determined to be the K40 relay and would be $300.00 to fix. So I parked it for five months until I could afford the work. While at the shop they tell me I need new IP DV seals and washers and should do the glow plugs. Ok so all that's done, now they say they can't get fuel out of number 5 and 6 nozzles and that I need to have the IP rebuilt to the tune of $1800.00. Does this seem likely? Car has 141,000 miles on it, has had impeccable maintenance (with exception to past 6 mo.) and started and ran just fine (just shut off when it felt like it). Could the pump just go to hell in a hand basket while sitting in the driveway? If this is so, can anyone recommend a reliable Bosch service dealer with better price to rebuild or can anybody tell me if they know anything about Santa Rosa Diesel. Thanks!

I'd be very surprised if the pump is shot, they are pretty Robust pumps... Methinks they may have done something wrong with your delivery Valve job, or there's an extrordinary amount of air left in the lines which seems unlikely giving they have fuel (assumed) at 1-4. As for a new working pump if it comes to that, You may be able to find one on here, Post a topic in the Parts area. when I was looking for a 603 pump I had several offers within hours. I hope someone else can chime in on the newer engines, There could me more wrong then just your K40 Relay. some other electronics may be out with the K40 or some codes in the engine. I doubt it would affect the Pump like that but oddball things like that could happen

[engatwork]

I'd be very surprised if the pump is shot, they are pretty Robust pumps... Methinks they may have done something wrong with your delivery Valve job

That is my thought too. Worst case situation now would be to take the pump off and get it to an authorized pump shop. I'm thinking your shop boogered up the delivery valve seal job on those two locations.

[TMAllison]

I'd have them redo #5 & 6 DV's. They've put something back together wrong. Hopefully they weren't overtorqued.

They engine can be started and run w/o the IM installed so they can do the DV's and crank or fire it up to see if that fixed the problem. If not, the IP can then be pulled and sent off.

Very few IP's go bad on thier own, they usually outlive the engine.

A pump rebuild is usually around $1000-1200 in shop labor.

[engatwork]

The first one I ever did I missed the pin with the slot of the barrel on one of the assemblies. I ended up having to remove the pump from the car and take it to a Bosch shop that was able to fix it fairly economically because they were able to adjust the pin a little. Bolted it back on the car and have not had any issues for probably 80k miles.

[babymog]

Agreed, sounds like a botched delivery-valve job.

You're probably going to have to take it somewhere else and have it fixed by someone who knows what they're doing, and good luck getting any money out of the shop that botched it.

Just consider yourself lucky if they didn't do any expensive damage and move on.