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#1
08-04-2003, 09:07 AM
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OM603 Shut Off Valve Replacement - Tips?
I need to replace the shutoff valve on my 300SDL. One of the bolts is out in the open, but the other is well tucked under a bunch of things. Short of taking off all of these parts, is there an easy way to get to it? Also, in the event the things do need to be removed, what else should I replace?
Thanks!
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Lance Allison Lance@LanceAllison.com Current: 11 MB S550 4Matic, 55k miles, Designo Black/Black 14 Ford F150 XLT Lariat Crew, 73k miles, 5.0 Coyote V8 4x4. Black/tan. 09 GMC Envoy Denali, 5.3 V8, 4x4 SWB. 38k miles, Jewel Red/Med Gray. Gone: 87 MB 300SDL, 320k miles, Astral Silver/Blue. 98 VW Jetta TDI, 488k miles, Classic Green/Gray. 85 Olds 98 Brougham FWD, 4.3 DIESEL V6, 80k miles, 3x Gray. MBCA Member, Chicago Region 
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#2
08-04-2003, 01:13 PM
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Lance,
To make the shutoff job 100x easier, remove the ALDA. Photos with instructions are at this URL: http://www.meimann.com/images/mercedes/OM603_injection/ You should also replace the O-ring for the shutoff pod at the same time (must order separately!). The MOST important thing to do is apply vacuum to the old pod and watch the metal external shutoff/stop lever travel. When you install the new pod, apply vacuum to that BEFORE you start the engine. Make sure the lever moves ALL the way up and down, same as the old one. Failure to do so can result in a runaway engine and a $5000 doorstop. Ask Larry, or search for his thread on this forum. This job is simple enough but you MUST be careful to verify installation (which requires a vacuum source, like a MityVac). Don't skip this step. Please. Good luck,
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#3
08-04-2003, 01:45 PM
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Pointers well received.
Thanks Dave!
__________________
Lance Allison Lance@LanceAllison.com Current: 11 MB S550 4Matic, 55k miles, Designo Black/Black 14 Ford F150 XLT Lariat Crew, 73k miles, 5.0 Coyote V8 4x4. Black/tan. 09 GMC Envoy Denali, 5.3 V8, 4x4 SWB. 38k miles, Jewel Red/Med Gray. Gone: 87 MB 300SDL, 320k miles, Astral Silver/Blue. 98 VW Jetta TDI, 488k miles, Classic Green/Gray. 85 Olds 98 Brougham FWD, 4.3 DIESEL V6, 80k miles, 3x Gray. MBCA Member, Chicago Region
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#4
08-04-2003, 08:32 PM
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As far as I can tell, it isn't physically possible to replace the servo without taking the ALDA off -- it only takes a few minutes and keeps you from sweating and swearing for hours....
Keep a 14mm wrench in you hand when you start up again -- leave the hood open. This will give you time to get to the injection lines it if runs away. Turn each open a half turn or so until the engine stops if it does, this will save the engine. It is very, very unlikely anything will happen, but be prepared! Peter
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1972 220D ?? miles 1988 300E 200,012 1987 300D Turbo killed 9/25/07, 275,000 miles 1985 Volvo 740 GLE Turobodiesel 218,000 1972 280 SE 4.5 165, 000 - It runs!
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