Om603 injection pump Leak - Page 2 - PeachParts Mercedes-Benz Forum

bkg322 · #16 06-20-2021, 10:17 PM

Quote:

Originally Posted by Diseasel300

Super common issue. Nothing will affect calibration. You need the splined socket to remove the delivery valve holders. YOu'll need new copper crush washers and new O-rings. There are lots of threads on this site and on the web with part numbers and procedures. Make sure everything is spotless before you take it apart.

Most critical part is the torquing. 30nm, release, 30nm, release, 30nm, final torque to 35nm.

You can do this job with the intake manifold in place, it's tight, but you can do it. Remove all the hard lines first to make it easier. Replace any broken or missing plastic clips and rubber bumpers, if they're missing the lines WILL break, usually right at an injector, or rub through where they vibrate on something else.

Can you tell me the dimension(size)of the O-ring?⁶

bkg322 · #17 06-20-2021, 10:21 PM

Quote:

Originally Posted by Diesel911

How to change the O-ring and crush washer will be in the Repair Links
Fast navigation Fast navigation Do It Yourself Links

Can you tell me the dimension(size) of the O-ring?

Diesel911 · #18 06-21-2021, 10:03 PM

The 2 past sources that sold the viton O-ring kits were alternative fuel sites they had I believe passed due the waning interest in the use of alternate fuels.
So you might have to use the Victor Reinz kit which on eBay was like $30. Someone may have posted the sizes of the O-rings but you would have to search the threads.

Diesel911 · #19 06-22-2021, 01:28 PM

Note I don't know if the below is the correct size info. Perhaps you could pull of one delivery valve holder and measure the O-ring and get some approximation of the size.

If you look up the Mercedes Part number for yours and the Mercedes Part mumber for the 606 that would narrow down the answer.

I've had no luck with Jim. He had a fire I saw in another thread and wasn't gonna be able to send any out. so I just got a bunch from mcmastercarr. I ordered extra to have in shop. I gotta check out how much they were but can mail you a set. I also got Viton fuel return lines. I could send you what you need.

This is what ya need more or less. You also need the copper washers for delivery valves if you do those. Not a bad idea while you have the intake off. I think I have 6 of those too.

*O-ring sizes for 606 *Diesel*
1 shutoff valve 2.5mm x 12mm ID
9 fuel line 2.5mm x 8mm ID (1 located at fuel filter housing)
3 fuel filter housing 2.5mm x 10mm ID
1 pre-filter 3mm x 18mm ID
6 delivery valves 2mm x 15mm ID (60x delivery valve )
4-5 feet Fuel return lines 1/8 ID 1/4 OD 1/16 wall

99 e300 diesel fuel line o-rings
99 e300 diesel fuel line o-rings

This has a list of threads that have information but for sure some of it is out of date.

“Viton hose and O-ring kit sources”
Viton hose and O-ring kit sources

Diesel911 · #20 06-22-2021, 08:43 PM

Another Forum superturbodiesl might also have information on the fuel injection pump O-ring sizes as people over on the forum fool with there fuel injection pumps more then on this one.

Felching · #21 06-22-2021, 11:41 PM

Quote:

Originally Posted by Diesel911

Another Forum superturbodiesl might also have information

lol, copied from other places. They don't have any original contributions to the diesel/mercedes community and haven't been relevant in over a decade. Some would say since they split from the Schuman forum fallout...

Diesel911 · #22 06-23-2021, 12:13 AM

Quote:

Originally Posted by Felching

lol, copied from other places. They don't have any original contributions to the diesel/mercedes community and haven't been relevant in over a decade. Some would say since they split from the Schuman forum fallout...

I never looked at the superturbodiesl forum much. I am just happy if my Car gets me down the road in a normal manner. However, that does not mean that in some thread there may be the dimensions of the 603 Fuel Injection Pump O-rings there.

My MW Fuel Injection Pump does not use O-rings up in the Delivery Valve area so I have never had a reason to keep track of the O-ring delivery valve O-ring issues.

Another thing is I am not as I will say picky as some. Harbor Freight sells viton O-ring assortments.

If I had the 603 pump I would remove one of the leaking delivery valve holders and see if I could remove the old O-ring intact and get some sort of an idea as to the measurements and take those measurements with me to harbor freight and see what they have in their viton assortment.
If there O-rings that I thought would work I would buy the assortment and perhaps replace just that one O-ring and see if it stops the leaking (you can sometimes put an O-ring on a part and turn it in by hand and see if it snug enough to seal or too tight).

If that worked I would be inclined to do all of them and hope for a reasonable longevity.

I would be more concerned with the crush washers. They don't have to be bosch (there is other companies that make kits for Bosch Fuel Injection Pumps) but sometimes the crush washers up in the delivery valve area are a stiffer alloy then just plain copper washers. So going out and buying an assortment of copper washers might not be a good idea because the torque spec is set up to match the alloy of the crush washer used.

glenlloyd · #23 06-25-2021, 08:47 PM

Quote:

Originally Posted by Diesel911

I never looked at the superturbodiesl forum much. I am just happy if my Car gets me down the road in a normal manner. However, that does not mean that in some thread there may be the dimensions of the 603 Fuel Injection Pump O-rings there.

My MW Fuel Injection Pump does not use O-rings up in the Delivery Valve area so I have never had a reason to keep track of the O-ring delivery valve O-ring issues.

Another thing is I am not as I will say picky as some. Harbor Freight sells viton O-ring assortments.

If I had the 603 pump I would remove one of the leaking delivery valve holders and see if I could remove the old O-ring intact and get some sort of an idea as to the measurements and take those measurements with me to harbor freight and see what they have in their viton assortment.
If there O-rings that I thought would work I would buy the assortment and perhaps replace just that one O-ring and see if it stops the leaking (you can sometimes put an O-ring on a part and turn it in by hand and see if it snug enough to seal or too tight).

If that worked I would be inclined to do all of them and hope for a reasonable longevity.

I would be more concerned with the crush washers. They don't have to be bosch (there is other companies that make kits for Bosch Fuel Injection Pumps) but sometimes the crush washers up in the delivery valve area are a stiffer alloy then just plain copper washers. So going out and buying an assortment of copper washers might not be a good idea because the torque spec is set up to match the alloy of the crush washer used.

I agree with the bit about the crush washers, IIRC when I did mine ages ago the actual crush washers for this application are very thin for the injector valve bodies.

Steve