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  #1  
Old 07-11-2018, 06:45 PM
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Location: Former New Jersey resident, transplanted to Atlanta
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1998 300E TD, fuel shutoff mounting bolt strpped

The common o-ring leak on a 1998 E300 fuel shutoff has returned..... I replaced the o-ring less than a year ago and it is leaking again

So, I figured I'd simply just change it again and when removing the fuel shutoff mounting bolts, the most forward one (the recessed one) stripped out on me..... I tried using an impact driver to get it to turn but did not want to get too aggressive for fear of possibly damaging the fuel pump or the shutoff.

I think I'm going to have to drill the head off of the bolt in order to remove the shutoff and then un-thread the bolt with pliers or vice grips.

Any suggestions?

Thanks in advance!!!

also, is there a PERMANENT fix for this leak?....... I'd really rather not have to do this every 6 months.
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2006 E320 CDI
1999 E300 Turbo Diesl
2002 ML500
1995 E320 Station Wagon


MBs I've owned
1997 E320 Assassinated by Pine Tree
1987 300E Wife Killed Engine
1981 300D Stretch Limo Total Loss
1970 250 Coupe 212,000 mi.
1974 450sel 184,000 mi.
1974 240D 377,000 mi.
1977 300D 204, 000 mi.
1979 280se God Only Knows!
1983 240D 130,000 mi.
1972 220D 280,000 mi.
1983 300SD 244,000 mi.
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  #2  
Old 07-11-2018, 07:52 PM
KyleMP012's Avatar
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Why not just use an extractor bit, they aren't that much and I've removed seized glow plugs with them, work like a charm. And it's most likely leaking cause you may have cross threaded the bolt and it never tightened properly. If torqued properly it shouldn't leak for at least another 5-10 years. It could also be the delivery valve seals leaking and the fuel running down the side of the pump.
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1999 E300D OM606, 278,000 km (Daily)
1984 Camry Turbo-D, 319,000 mi (Sold)
1992 300D OM602, ~450,000 mi (Sold, Blown Head)
1999 F250 7.3 Powerstroke, 243,000 mi (Sold)
1996 VW Passat TDI 110,000 mi (Sold) "The first Diesel"
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  #3  
Old 07-11-2018, 08:33 PM
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Great idea but where can I find a T30 metric torx extractor bit?
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  #4  
Old 07-12-2018, 02:24 PM
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Left hand drill will usually back out something like this. You can get a cheap kit in various sizes with EZ outs. Use one a little smaller than the screw diameter at first. If the left hand drill doesn't back the screw out, go in a little and switch to a size a little bigger than the screw, it will take the head off it. With the head off, you can remove the valve, grab the remaining stub with vise grips and break the loctite. Should come out with your fingers at that point.
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  #5  
Old 07-14-2018, 03:53 PM
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Ok, so....last time that I replace the fuel shutoff o-ring I was able to access the two torx bolts without taking the manifold off...... This time, I have to because (and it's my fault) when I reinstalled the shutoff screws I overtightened them.... I remember turning them both that extra quarter turn.... duh!!

Anyway, looks like I'm going to have to pop the heads on both of them as the other stripped as well...... Does anyone know what size the bolts actually are, as in length and thread mm size?...... I'm going to have to try matching them with replacements that will more than likely not be torx head bolts!

Thanks,
__________________
Currently Driving
2006 E320 CDI
1999 E300 Turbo Diesl
2002 ML500
1995 E320 Station Wagon


MBs I've owned
1997 E320 Assassinated by Pine Tree
1987 300E Wife Killed Engine
1981 300D Stretch Limo Total Loss
1970 250 Coupe 212,000 mi.
1974 450sel 184,000 mi.
1974 240D 377,000 mi.
1977 300D 204, 000 mi.
1979 280se God Only Knows!
1983 240D 130,000 mi.
1972 220D 280,000 mi.
1983 300SD 244,000 mi.
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  #6  
Old 07-15-2018, 12:58 PM
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Join Date: Jan 2018
Posts: 215
I think they were 5mm. Can check here in a few when I open my shop. Thought I had lost one on my firend's car and grabbed one from work. If you go with a different bolt, they are an odd length. I had to cut a longer bolt down about 4mm to get the exact length. Also you will have to use an allen head bolt if not the torx. There is not room to get a socket on a hex head.
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  #7  
Old 07-15-2018, 02:20 PM
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6mmx1 25mm under the head. Only had 20 or 30mm at work, so cut down a 30mm.
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  #8  
Old 07-16-2018, 08:34 PM
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Location: Former New Jersey resident, transplanted to Atlanta
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Had to order the bolts from the dealer as they did not have the bolts in stock, also ordered new o rings for the plastic lines but the dealer could not find copper crush washers for the lines. How tight should the bolts be? I purchased a new shutoff valve as O do not want to revisit this repair again.
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  #9  
Old 07-16-2018, 10:21 PM
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Couldn't actually find a torque spec, so I ran them down firmly with a 1/4" ratchet choked up on the handle (head of ratchet in hand) and used blue loctite last time. When the valve itself turned out bad on my firend's car, I had to remove the loctited bolts again. No problem. Put them back in the same way.
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  #10  
Old 07-17-2018, 02:20 AM
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Join Date: Apr 2016
Posts: 790
The shutoff valve is plastic. Maybe you can just break it up and remove it, exposing the torx head bolts that hold in onto the injection pump. That would let you remove the bolts with pliers. The shut off valve costs about $150. [This might not work if there are metal sleeves that line where the bolts go through the valve.]

You can get new bolts from the parts desk at a Mercedes dealer. I thing the bolts they now sell have 10 mm heads. I heard from someone [parts guy at Mercedes or Peach parts] that the '99 e300 has 10mm bolt heads as original equipment for the same shut off valve as on the '98.


I've owned a '98 for more than 11 years and have changed that O ring twice. Neither of the ones I took off was leaking and the one most recently installed does not leak. I've used the original bolts the times I changed to O rings and just tightened them so they were pretty firm but not enough to strip the aluminum threads.
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  #11  
Old Yesterday, 12:53 AM
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There are brass bushings about 1/2" in diameter set in the plastic. Trying to destroy the plastic to get the bolt out would be futile. I may be wrong, but I really don't think a 10mm hex head will allow a socket to fit, that's why the torx or Allen head.
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