603 Injection Nozzle leak - Help!
 

1987 300SDL
just turned 300k

My injection pump is leaking fuel at the top around the nozzles. I have read posts regarding changing the o-rings on the nozzles. My 603 differs from the 5 cylinder with regards to removing the nozzles. Insted of a standard six point socket, it requires a splined socket to remove the nozzles. Most of yesterday was spent trying to locate the tool. The 3rd MB dealer I visted told me the nozzles were factory set and not to remove them. His estimate was based on shop removal of the entire injector pump, sending out for repair/rebuild, and re-installing the pump using required electronic timing adjustment equipment ($700-1200 pump rebuild, + 4 hrs r/r $$$). Oooouuch!

Just spoke with a trusted all MB non-dealer repair shop and was told I was looking at an hour or two to remove nozzles and replace orings (+/- $125 repair).

If it's just o-ring replacement, I think I can handle it.

ANY EXPERIENCE WITH THIS????

Where can I get the socket?
Anyone have the torque number for the nozzles?

thanks,

DZLPWR

I think you're talking about delivery valve seals, not injector nozzles. Search for "delivery valve seals" in this forum and you'll get some good info. Here's a post with the torque procedure:

603 IP Seal Procedure

so much for my CD manual using proper wording.

I'm refering to the pieces that the lines attach to which are located in the top of the pump.
Delivery Valves sounds good to me.

Thanks Rick

thanks again Rick,

I found the 30/30/35/35 torque setting. Phill is working on a socket.

should be good to go.

Hmm... my CD manual is makes a reasonable distinction between nozzles and delivery valves. Check out procedure 07.1-210.

The 603 uses the same delivery valve splined socket as the 617. It's available from many on-line sources for $20-30 if I remember. No way around that. The 6 point socket for the nozzles probably refers to a 27mm deep socket for what the forum calls injectors. I use the cheapest socket I found at Home Depot with no problem. But that's neither here nor there since you don't have to touch the injectors.

If you can't manage to work on the delivery valves with the intake manifold in the way, consider other things to check while the intake manifold is off. Things like the stop valve, glow plugs, injection line clips... I don't know what the manual calls these items ;)

Sixto
91 300SE
87 300SDL
83 300SD