Success! Many many thanks for the link!

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1982 300GD Carmine Red (DB3535) Cabriolet Parting Out
1990 300SEL Smoke Silver (Parting out)
1991 350SDL Blackberry Metallic (481)

"The thing is Bob, its not that I'm lazy...its that I just don't care."

Or maybe not.......

I got all the injection lines off and all was going well. I pulled the first valve off and put the new rubber o-ring on the valve body and placed the new copper o-ring down. So far so good.

When I went to screw the valve body back into place and it wouldn't catch on the threads no matter what I tried. Turns out that the old o-rings are 13mm in diameter and the new 14mm rings don't fit despite giving the correct part number to the Bosch repair shop. The copper o-rings are supposed to rest at the top of the valve body but these won't even fit inside.

I got quite frustrated with the situation and even thought about filing down the washers to make them fit. However I thought "Let me check something." Some years ago I ordered an o-ring kit from the dealer for my 603 engine to do the same job. I only replaced one of the seals last winter and still had a few left. Well wouldn't you know it, the copper washers for the 603 are the same size as those for the 617! I even have the bag with the part number which is A 004 997 45 40

I'm surprised that this fact hasn't been picked up on before or am I missing something.....

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1982 300GD Carmine Red (DB3535) Cabriolet Parting Out
1990 300SEL Smoke Silver (Parting out)
1991 350SDL Blackberry Metallic (481)

"The thing is Bob, its not that I'm lazy...its that I just don't care."

I'm not sure how relevant this is but thought this was interesting. (My SD engine shakes and I think delivery valve seals may be next on the list.) This page came up when searching on the PN above. ("A 004 997 45 40 injection")

Bosch diesel injection pump disassembly pictures

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85SD 240K & stopped counting painted, putting bac together. 84SD 180,000. sold to a neighbor and member here but I forget his handle. The 84 is much improved from when I had it. 85TD beginning to repair to DD status. Lots of stuff to do.