Fellas -- I've stopped a bunch of leaks on my '82 SD, but my injection pump is leaking from these two areas:

(This is not my pump. Mine's still on the car)



Anyone have experience with leaks in this area? Should I just pull the damn thing and reseal it? Looks very close to a nightmare the get any tools on it and tighten it from the bottom. Especially with the oil can in the way.

It's bone-dry on the top and I recently replaced the primer. Could bio-d have eaten the gaskets at these seams? Are there even gaskets at these seams?

What to do, what to do. Thanks in advance!

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1998 E300 +310,000K
1996 E300 +460,000K

From my many years of experience with Diesels, mostly of ships, and seeing as how you already have the pump off, I would take it to an injector shop and get it gone through or exchanged for a rebuilt. The insides of these pumps is not for the feint of heart. Plus it is probably 25+ years old and needs an overhaul and re-calibration anyway. It won't be cheap but you will probably never have to worry about it again for the life of the car.

..

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1998 E300 +310,000K
1996 E300 +460,000K

The rear cover uses gasket 001 074 46 80.

The bottom cover uses gasket 003 997 77 40.

I can't tell from your arrow whether the forward leak is from the bottom cover or the seam between the front and rear halves of the IP. I'm pretty sure splitting the IP isn't for the first time DIYer.

Sixto
93 300SD 3.0

Bottom cover?! See, that's the info (I hope) I was looking for. I haven't been able to isolate where that particluar leak is. My hope is that it is the bottom cover and maybe, just maybe, I can tighten it or replace the gasket without pulling the pump.

Thanks, that gives me more info for when I actually climb in there for a better look-see.

Next question for those who've done it -- Can the rear and bottom covers be removed to replace those gaskets without disturbing pump internals? What should I do with the rack damper? Leave it in place? Mark it's position and remove it prior to rear cover removal?

Even though I've rebuilt countless hydraulic pumps, electro-pneumatic pumps, compressors, motors, engines, restored a number of vehicles, designed, built and installed machinery control centers, etc, etc., I'd rather not completely pull this thing apart.

My car runs so well. I just don't want to go through the hassle of R&R'ing this pump if I can stop the leaks whilst on the car.

Thanks for the tips so far.

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1998 E300 +310,000K
1996 E300 +460,000K

did the leaks start after you replaced the primer pump?

Is there a possibility that the base of the primer pump is leaking, making it appear that the IP is leaking?

just a thought....

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Cheers,
Robert

No. Been leaking since I got the car.

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1998 E300 +310,000K
1996 E300 +460,000K

Finally entered the right search keywords!!!

http://www.detali.ru/cat/oem_mb2.asp?TP=1&F=123132&M=617%2E912&GA=722%2E118405&GM=716%2E005++++++++++++++717%2E400&CT=M&cat=143&SID=07&SGR=045&SGN=01

(Link posted by the ever-gracious t walgamuth)

Still gotta pull the oil can, but i think I can stop these two leaks with the gaskets Sixto showed me and a little bit of time!

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1998 E300 +310,000K
1996 E300 +460,000K

What does it cost to have a pump recalibrated? Who does this sort of work?

Best to have it done by a Bosch shop. Gus Pfister of Pacific Fuel Injection in South San Francisco charged $800 a few years ago. Pretty steep since you can get exchange units go for less but Gus is known for knowing his stuff.

Sixto
93 300SD 3.0

When mine started leaking about a year ago (maybe ULSD?), I just replaced it with a reman unit (about $850, as I recall), there was no point messing with a 300K mile IP if having it services will cost as much as a "new" one. It also smoothed out my engine noticeably, the old one must have been weak (uneven) anyway.

BTW, if I remember correctly, metric motors recommended "Gus" for IP work when I called them looking for a reman IP.

So, those gaskets don't exist anymore. Well, one of them does, in germany.

Anybody got a decent used IP they want to sell?

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1998 E300 +310,000K
1996 E300 +460,000K

I don't know about 617 IP gaskets but all 603 IP gaskets yopu can replace externally are available from MB or Phil. Only the stop lever shaft o-ring is not available and that's an easy one to size-to-fit. Unfortunately the control rod sensor o-ring is a common leaker so a lot of reseal jobs fall short of stemming leaks completely.

Sixto
93 300SD 3.0

Cool. I'll hit up Phil. Thanks.

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1998 E300 +310,000K
1996 E300 +460,000K