95 OM606 Stalled..Read On if you dare... - PeachParts Mercedes-Benz Forum

stcbenz83 · #1 04-17-2013, 08:58 AM

Hello fella's, been a while since ive posted. So my 1995 E300, which i am in the process of getting ready to sell, all of a sudden sputtered and stalled out on me!!!

Haven't EVER had an issue like this before.

Some back round; The previous Saturday, I took the IM off to replace the main fuel platic line where the return and the main fuel line hook into the housing. Also, Hot tanked my IM

whand some other minor repair. Ran like a champ, and way quieter for a few days then, yesterday I was getting ready to leave to run some errands, letting it warm up, was getting a bunch of 'clacking' then, the clacking became louder and a few shakes later, the engine stalled. Like I was out of fuel.

So, If I fill up the secondary filter, I can get it to fire and stay running long enough to check the fuel lines. 2 THINGS I NOTICED ARE:
the fuel line going to /and/ coming from my feed pump/fuel pump or whatever you want to call it had an insane amount of air bubbles running through it. Both back and forth (on the 2 lines that connect to that lift pump only. My main fuel line looses 'prime' when it stalled but fills as soon as it's started so, my concern are all these air bubbles.

Secondly. When I remove the secondary fuel filter, It is SUPER pressured and sprays fuel everywhere if your not careful when removing it.

So, I guess my question is, does this sound like a feed pump that has gone bad? or a Fuel Pressure Relief/Overflow Valve that's not venting properly (which is the bolt I took out when I replaced the main clear fuel line?

Thanks for your guys help, as always! Really wanting to get my 240D back on the road and, have decided that I Can't have 2 'project' cars. I've put countless man hours and over $4,300 in parts alone into this (money well spent IMHO as it finally drives like a Mercedes should, just wont start now

)

So anyways, its suppose to be raining hard the next few days, want to be prepared this weekend so I can get this back up and running so I can sell it. Until then, Ill have to drive the Ranger.

Zulfiqar · #2 04-17-2013, 09:07 AM

I would suggest you first try to run it direct off a gallon bottle of diesel fuel. If your secondary filter is getting pressure in it then the only two bits that can do it are the banjo on the pump or the one way check valve on the return line to the tank - its right behind the filter with a 90 degree angle hose on the middle line of the secondary filter facing to the back of the car. (It was a later add on by MB, so not all cars would have it)

It would also not hurt to replace the O rings on the clear fuel lines and then check for leaks

barry12345 · #3 04-17-2013, 09:17 AM

This based on your description of the heavy fuel pressure you see. Or more likely the air compressing the fuel and when you loosen the filter the compressed air contained in the system after the lift pump drives the fuel out.

First of all I would chase down where the air in the system is coming from or getting in. I actually see no other choice by your description. Also suspect it is before the lift pump.

martureo · #4 04-17-2013, 09:19 AM

Quote:

Originally Posted by stcbenz83

Hello fella's, been a while since ive posted. So my 1995 E300, which i am in the process of getting ready to sell, all of a sudden sputtered and stalled out on me!!!

Haven't EVER had an issue like this before.

Some back round; The previous Saturday, I took the IM off to replace the main fuel platic line where the return and the main fuel line hook into the housing. Also, Hot tanked my IM

whand some other minor repair. Ran like a champ, and way quieter for a few days then, yesterday I was getting ready to leave to run some errands, letting it warm up, was getting a bunch of 'clacking' then, the clacking became louder and a few shakes later, the engine stalled. Like I was out of fuel.

So, If I fill up the secondary filter, I can get it to fire and stay running long enough to check the fuel lines. 2 THINGS I NOTICED ARE:
the fuel line going to /and/ coming from my feed pump/fuel pump or whatever you want to call it had an insane amount of air bubbles running through it. Both back and forth (on the 2 lines that connect to that lift pump only. My main fuel line looses 'prime' when it stalled but fills as soon as it's started so, my concern are all these air bubbles.

Secondly. When I remove the secondary fuel filter, It is SUPER pressured and sprays fuel everywhere if your not careful when removing it.

So, I guess my question is, does this sound like a feed pump that has gone bad? or a Fuel Pressure Relief/Overflow Valve that's not venting properly (which is the bolt I took out when I replaced the main clear fuel line?

Thanks for your guys help, as always! Really wanting to get my 240D back on the road and, have decided that I Can't have 2 'project' cars. I've put countless man hours and over $4,300 in parts alone into this (money well spent IMHO as it finally drives like a Mercedes should, just wont start now

)

So anyways, its suppose to be raining hard the next few days, want to be prepared this weekend so I can get this back up and running so I can sell it. Until then, Ill have to drive the Ranger.

I had the same problem. I ended up replacing all of the clear fuel lines and all the injector return lines trying to hunt down the air leak (which is probably what you have).

I ended up replacing the from tank and return to tank lines and I've never had the problem again.

It's air getting into the system. The fuel system will run for a bit and then won't get enough fuel at some point due to air getting in. I'd start with wiggling lines around, replacing them if they are old and non-clear and then consider the lift pump seals.

It is a FRUSTRATING ordeal, you have my empathy. It took me a full week to hunt down what the heck was going wrong.

stcbenz83 · #5 04-18-2013, 02:48 PM

INDEED Very frustrating! It's been pouring here the last few days and garage space being limited... I'm going to start with the 2 lines going to and from the feed pump as that's where I see the most air pockets... Also, I'm wonder, while I have that stupid IM off..AGAIN if I should double check that pressure bolt that the main fuel/return line connects at the IP.... Thanks guys for the help! I'll keep you posted!

Jadavis · #6 04-18-2013, 02:53 PM

Clogged return line to the tank?

stcbenz83 · #7 04-18-2013, 02:56 PM

Quote:

Originally Posted by Zulfiqar

I would suggest you first try to run it direct off a gallon bottle of diesel fuel. If your secondary filter is getting pressure in it then the only two bits that can do it are the banjo on the pump or the one way check valve on the return line to the tank - its right behind the filter with a 90 degree angle hose on the middle line of the secondary filter facing to the back of the car. (It was a later add on by MB, so not all cars would have it)

It would also not hurt to replace the O rings on the clear fuel lines and then check for leaks

I am Getting pressure in both filter's... the one way check valve was replaced last year (one of 3 left in the country I was told) in order to help with cold starting.. never really did anything and cost me $75... Maybe Ill try swapping the old check valve in?

I have a feeling the line lowest on the filter housing (believe it going from the primary fuel filter to the lift pump) to be the culprit... We shall see. Did have it running for a while but those air bubbles going to and from my lift pump kept me from taking it on the road.

Ill keep ya'll up to date though

stcbenz83 · #8 04-18-2013, 03:10 PM

Quote:

Originally Posted by Jadavis

Clogged return line to the tank?

Ill try blowing the lines with compressed air and see if that helps as well.... Might as well since I've to remove the IM... again heh...

Zulfiqar · #9 04-18-2013, 03:42 PM

the primary filter O ring can leak a lot of air into the system. Remove and check it, also apply some ATF on it before pushing the filter home, otherwise the ring gets pinched.

The other bit that can cause headaches is the rubber pipe coming from under the washer tank upto the fuel heater connection, if its a bit wet looking replace it now, its leaking.

As mentioned a few posts above air can get compressed in the system and cause this pressure too.

Chris W. · #10 04-18-2013, 09:08 PM

It's not clear to me whether you may have removed any of the plastic fuel lines while you were working on things, but if you did, I'd say there was a good chance you may have swapped position on a couple of them or mis-routed them.

I remember when I changed my lines, there were a couple that could fit in more than one way. I had to look back at the photos I had taken and the parts diagram to make sure everything was routed properly.

Rgds,
Chris W.
'95 E300D, 391K

stcbenz83 · #11 04-21-2013, 07:35 PM

Got It!!

Chris W- I was hoping and, crossing my fingers that it wasn't something as you had mentioned. The only fuel line I replaced while the IM was off was the main fuel line "" I'm going to call it (the one furthest left and, that the main fuel hose/line connects with). Behind -or- what attatches that line to the side of the IP is the 'pressure release' bolt to the side of the IP.

Luckily!!...
I replaced both the lines that go from the filter housing to the lift pump and, that did the trick!! Filled the Secondary w/ Diesel Purge and cranked....and cranked... and finally sputtered back to life!

The line going from the bttm of the Primary Fuel Filter was super suspect and, believe is what caused the whole situation. However, after replacing both lines, WOW!!! Better starts, Less 'clacky', smoother idle, and really helped my w/ my transmission's shift quality! Not to mention the POWER I never knew I had!!!

So She's back in service, running better than ever! Best part, took only an hour (once I had the parts...correct parts...darn Worldpac sending the wrong seal's

) Best part was NOT having to remove the IM AGAIN!!!

Thank's Again Everyone for all the suggestions, comments, etc... Helped me think it through and point me in the correct direction!!!