Uh oh! Time for delivery valve seals. 1999 E300 OM606
 

At least I think so.

I'm not seeing any major fuel consumption issues yet, just smelling diesel for the past couple of days.

Dug out the flashlight and looked at the top of the IP and sure enough, it's really damp with fuel.

I'm wondering how long I can put this off until I can dig into it. I've got a car down already, and cant put it back together until I have all the ducks in a row, so to speak.

I can't have two cars down at once, because that will leave me renting a third just to get to work.

Hmph :(

As long as you don't mind the leaking fuel it should not really be any issue to continue driving it.

That was my hope.
 

I know it's not the most challenging task in to world, but I do not like to rush any repair job.

I have a pan to put under the car if the drooling problem gets too bad.

I'm wondering if this had manifested earlier than now and was the reason for my stumbling starting issues earlier.

You know you need to, you know you want to, so take the plunge - it's not that bad. Seems like I did it last year, or fall before. A quick shot before I buttoned everything back up.

http://i878.photobucket.com/albums/a...BE300IM002.jpg

Do a search and read over the procedure carefully, i.e. torque values, how much of the delivery valve to remove, etc. Some folks have jumped right in and came out the other end much wor$e than they entered the project.

+plastic lines & shut-off valve
 

I just had the same problem @189K on my '99.
had all the plastic lines replaced along with dv seals. discovered shut-off valve leaking as well after it was all buttoned up.... off w/the manifold again +$160 for a little lump of plastic, but no leaks/fuel smell now.

Aye.

Aye.

I know that it's not that bad, but even just changing the thermostat or alternator on this car became a multi-day event. Every time I take something off this car, there seems to be 'underlying issues' that have to be addressed. Either that or I have to wait for special tools or parts to be delivered, even though I thought I had everything.:mad:

Yep. I am ever cautious about 'fixing' things when the 'fix' ends up ruining things in the process.:(

I might see if my local mech. can tackle this task. I really don't have time right now. O-rings are cheap, mech. labor is expensive, and my time is priceless and far too limited.

Update: The chore has started!!!
 

Okay folks,

I did contact my mechanic to see what he would charge for this job. His quote came to $425. Which is probably not that bad, but I am a frugal sort of person... usually.

So, after much debate, and plenty of research, I've decided to tackle this myself.

Day one: Removed underpans, plastic injector cover, intake manifold, battery terminal. Plugged intake ports, EGR pipe and plenum tube with paper towles and put underpans on a drip pan to let the diesel drain out of them.

Tomorrow: I will set the IM to soak with Marine Clean, and start cleaning/inspecting the injection pump, lines etc to better determine what is leaking.

There was diesel all over the side of the engine and the underpans were soaked. I did see diesel around the tops of the DVs on the topside, but there was a significant amount of diesel that may have been leaking from behind the SOV as well.

Thursday/Friday: I plan on replacing all o-rings and return lines with viton, changing the filters, running a couple cans of diesel purge through the system.

I also plan on cleaning and checking the EGR to ensure that it fully closes (was getting a lot of whistling from the turbo lately and the EGR did stick one cold night) and replacing all the vacuum lines/connections that actuate the EGR and turbo wastegate.

After all this I think I should be good for a while... I hope. :o

That is always a beautiful sight. A clean and cared for OM606.:D

Uh oh! Time for delivery valve seals. 1999 E300 OM606
 

Looks like I need to replace a hose and return plug on #6 injector as well.

DV seals done, waiting on a new return line hose from Germany.

The job was about as stressful as I thought it would be. I need to do SOV & seal as well as clear line o-rings before buttoning everything back up.

Luckily, I had a return line plug for #6 injector in my parts bins. Those are like $7 now!