Hi all
Over the Christmas holidays I replaced the o rings crush washers on my om603s delivery valves, got the car started somewhat easily but, blue smoke way rough idle and last night I finally drove the car for more than a few minutes and it seemed to not have any power ran like dog doo doo. I had done a diesel purge a couple days ago and it seemed to help. But it’s running really bad now. The idle smooths out a little when warm.any Ideas about tests i could do to isolate which cylinder is messing up ? Any help greatly appreciated. Btw ran great before I messed with it.

This applies to M type fuel injection pumps; the ones that need the special splined socket to remove the delivery valve holders.

It is a typical problem when some do the O-ring and crush washer replacement. Without knowing it the pull up one of more of the barrels and get that barrel out of alinement and the assemble it like that. When that happens, that barrel is no longer aliened/timed, and it can't deliver the proper amount of fuel.

If you torqued it to inch pounds/pound inches doing that usually does not damage the pump housing. If you torqued it to foot pounds/pound feet and the barrel was lined wrong or even lined correctly you can damage the aluminum fuel injection pump housing.

See the picture in post number 4. If that barrel gets pulled up and does not go exactly straight back down the alinement pin won't go into the groove.

220D injection Pump

See the picture in post number 2.

Om603 injection element

What you are looking for in the picture is towards the top of the picture with the side cover off you see steel pins driven in and staked. Typically, when one of the barrels out of alinement and tightened down it pushes one of the alinements pins out. And you can see that with the cover off.

If the pin was not pushed out, you can remove all of the hard lines from the top of the fuel injection pump and lay a straight edge across the top. When you do that, the straight edge should touch all of the tops of the delivery valve holders. If one or more are higher than the lowest ones that is where the problem is.

Not even when I worked in a fuel injection shop maybe one or 2 times a year it would happen to me.

I tried to remember to turn all of the delivery valve holders down just enough to bottom them and before I torqued them, I looked to see if they were all the tops of the delivery valve holders were level with the others.

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84 300D, 82 Volvo 244Gl Diesel

You may need to pull pump and get it to an authorized Bosch shop. I would suspect barrel out of alignment issue.

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Jim

Update
Looked at it this morning after I got it started and noticed fuel leaking and bubbling at the #6 injector, removed the fuel line and the collar slid right off, I then noticed the nipple thing was broke off where it went who knows must be on the driveway or someplace. I had set of hard fuel lines for a 602 in garage and “made one work” wow what difference.
Warm start seems back to normal I need to let it cool to see about cold start.smoke gone