91 300D Leak on Injector Pump

[MeinGreaseCar]

Have a leak on top of IP. Picture below.

Blew it out with compressed air. Appears (assuming numbered fore/aft) Number 2 and 5 leak at the base of the knurled connector (delivery valve???)

Leak is NOT coming from the connector where the fuel line connects.

Crush gasket is what I find when I look on here. Car is a very lightly used 1991. I bought it a few years back with 27k on it. It's got 55k on it now.

Leak seems to continue after car is shut down. (stored pressure bleeding out over a long time?) Car was in storage all winter and leaked a fair amount onto the floor, and filled a bunch into plastic belly pan.

JP

[shertex]

Looks like delivery valve seals need to be replaced. I guess your car is proof that they can fail due to age rather than use.

[vstech]

it's not the crush washers that leak... but they do need to be replaced. it's the rubber o-ring that fails... another reason the 61x motors were better... no rubber seals on the DV...

it's a SERIOUS torque sequence, multiple steps, you need an accurate torque wrench and a lot of patience to change them.

[Maxbumpo]

Special "splined" socket required to remove the DV. Do one at at time. Clean clean clean! Tooth brush and brake cleaner, compressed/canned air, the slightest bit of contamination may damage DV and/or injector.

Replace O-ring, copper washer, and spring for each DV.

Torque sequence: Torque to 30Nm, release. Torque to 30Nm, release. Torque to 30Nm, then torque to 35Nm. Apply locking tab.

Once all the DVs are completed, start and run the engine while listening to the injector pump. If you can hear any additional noise from the injector pump, the body is warped. Loosen and re-torque all the DVs.

[MeinGreaseCar]

Sending page printout to my Indy. He's pretty good. will be honest if he can do it .


JP