PLEASE help! E300 Diesel leaking fuel. - PeachParts Mercedes-Benz Forum

95e300man · #1 04-08-2004, 04:05 AM

Hello All,

I am the discouraged new owner of a 1995 E300 Diesel (606 engine) with 102K miles. I barely have had the car a week when it started leaking diesel fuel. The mechanic has to take off the intake manifold (6 hours book time for the whole job) to get at the injectors and something about 6 washers or seals or something where the leak is coming from. They said that they called a Mercedes dealer and they don't sell the washers or seals, etc alone and that you would have to buy a $1500 rebuilt fuel pump. That is hard to believe. The shop ordered some washers or seals (6) from a generic diesel place hoping they will work? Is their a Mercedes part number for these? Where can you buy them? I still don't fully understand this situation, but this particular leak appears to be common to the E300 and 606 engine. I sure hope this is one of the biggest and most common issues and that the 606 engine is relatively trouble free from here. I owned two other diesels '83 300td and '80 300sd in the past.

Thanks you,
Edward

slowmoe · #2 04-08-2004, 08:30 AM

Edward,

It sounds like you are experienceing a common issue with these engines. As the car ages, the plastic fuel lines and rubber gaskets get brittle, crack and leak fuel. There are several posts regarding this.

First, don't pay a dime to the person who wants to charge you 6 hrs labor to pull the intake. The FIRST time I did it, it took about 30 minutes and I am not a mechanic by a long shot. A complete set of lines and gaskets can be had from this site (phil at partshop) for a few hundred dollars. If you are a moderate DIYer - it may take you a few hours. I personnaly have not done this job - probably will need to soon.

Second, please do a search on E300, fuel leaks, intake etc... I am sure you will have most of your worries set aside.

Finally, I would ask you if you are taking your car to an MB specialist. If not, I would highly recommend that you do so in the future. If you are, then maybe I am wrong and there is a more serious issue.

Rick Miley · #3 04-08-2004, 10:28 AM

It's really hard to tell third-hand, but sounds like they are talking about the copper washers on the injection pump at the hard lines. They are known to leak as well, but mine have never been a problem. If the local dealer is not being cooperative on parts, then have your shop call Phil at Fastlane. Click the "Fastlane" button at the top of the page, and you should find the phone number.

And hearing of the 6 hour estimate, I'm suspicious of your shop as well.

95e300man · #4 04-08-2004, 11:33 AM

The part that they need to replace on my om606 engine is the delivery valve seals on the injector pump. There are 6 of them according to them. Hopefully I can order these?

I am thinking I may have them replace the glow plugs while the intake manifold is off and check the wiring harness.

Rick Miley · #5 04-08-2004, 01:00 PM

Make double and triple sure they know exactly how to replace the delivery valve seals. There is a specific procedure for torqueing them down that, if not followed, can ruin the injection pump.

Phil at Fastlane should be able to get any parts you need.

TMAllison · #6 04-08-2004, 01:46 PM

I recently had this done on my 99 E300 at a cost of ~$440. This was at the dealer! Majority of cost is labor related to removal of intake manifold, not seals.

Use a good independent mercedes specialist or the dealer. Period.

Mark Herzig · #7 04-08-2004, 02:27 PM

hang in there buddy... I just finished this exact procedure and have pictures... do a search under my name or fuel leaks E300D.

Agreeded that the intake removal is not bad at all... IF I was to do it right now (knowing what I know NOW), it would take 15 minutes. That includes a mid-point beer refill.

There are so many LITTLE things that can leak that is is highly probably that is has nothing to do with the injection pump proper. You will see from my post that I replaced all of the fuel lines (total cost around $70). The real problem was a pin size hole in one of my metal injection lines. It sprayed fuel everywhere so one would think EVERYTHING was leaking...

So do not commit to costly IP repair when,. probably, it is an 'o' ring or something similiar...

One point, if unsure where the leak is, it is a good idea to remove the intake as you can maneuver freely. It is possible to replace the plastic fuel lines with ONLY the crossover pipe off but I'd reserve that procedure for times where you specifically / unambiguously know where the leak is.

95e300man · #8 04-08-2004, 09:54 PM

Thanks for all of the support and info...

I bought the E300 prepared to assume the risk of a few expensive repairs here and there. I am not regretting the decision to buy it right now. Fuel leaks are supposedly common, so I am going to hope that fixing these fuel items will nail one of the major common problems that I should see.

It turns out that only part of the 6 hour total time was for the removal and reconnect of the intake manifold. A good part of it supposedly is for the work being done to the fuel pump injector, replacement and fabrication of lines, etc. I called fastlane and a few others and apparently there is not a Mercedes part for what I need. They are gaskets on or in the fuel injector pump that are leaking. My repair facility is an independent shop that specializes in Mercedes as one of the brands. After talking with them, and with the info you gave me, I feel a little better about just getting it done although I know I could save some nice money if I had the time to do it myself (swamped with work at the moment). They are getting the gaskets, or rubber rings for the pump from a Bosch certified rebuild facility. They are seals that are either on or in the fuel injector pump. Several Mercedes parts departments would rather you just replace the whole pump. While they are down there, they are going to replace the fuel lines, etc just to be safe. So the 6 hours is for all of that work if it means anything. I was talking to the dumb shop admin who scared me and said something about possibly having to get a rebuilt pump at $1500, but it turns out the mechanics are going the Bosch shop route to get around that situation. The problem is that the shop admin/secretary is a real beaurocrat. When you actually talk to the owner and mechanics, you get a totally different feeling/story.

They seemed pretty legit when talking to them and the owner/master mechanic in person. They are still marking up items and I am sure they are making good money like most shops.

So the car is in superb condition, but I do not have the service history, I am going to change all fluids and filters. I am using Amsoil 15w-40 Heavy Duty Diesel Synthetic, Amsoil ATF, and Amsoil Differential fluid. Coolant is Mercedes. Brake Fluid is Mercedes Spec Dot4, etc. Flushing break fluid, power steering, etc. Hopefully this preventive maintenance plus the fuel leak fix will keep the beast out of the shop for a while.

I have got to believe that I knew what I was doing when I carefully chose the 1995 W124 E300D as my highway beater. I have a 2003 X5 with 9500 miles for around town. The idea is for the E300 to take all of the highway miles off the X5 when I travel to all of my distant clients here in California. I also plan on using it for some runs to my condo in Vegas. My mom asked me if I should do the opposite with the cars and use the older Benz around town. Hell no! The E300 is the ultimate highway cruiser. The BMW is much better suited for quick stop and go city driving and canyon twisties. I am looking forward to the cheaper gas and great mileage on the E300. The X5 is 17.1 mpg combined!