tool list for 603 delivery valve seal job

6mm ball point allen socket (can use a regular allen socket with swivel)

5mm allen

T30 star socket

10mm - 1/4 drive socket

6" - 1/4 drive extension

1/4 drive ratchet

crazy delivery valve socket (mine was 1/2 drive)

1/2 drive ratchet

torque wrench (needs to go as low as 22 foot pounds or 30 newton meters)

14mm combination wrench or crowsfoot

magnet

hemostats (long)

Pick

It's nice to have a magnetic tray

Grease (white or whatever)

Air Compressor with air gun (to blow off any debris)

Rags

ATF

Carb Cleaner

Scitchbright pad or equivalent

Flashlight or some kind of light

Camera (it helps to take a few pics if you think you might get lost putting it back together)

Parts

O-Rings (x6)

Crush washers (x6)

Intake to head gasket (do not reuse)

Intake to intake extension elbow gasket (it is possible to reuse this one but better to replace)

Any update on your 603 DV problem?

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Dave
Boise, ID
Check out my website photos, documents, and movies!

You might have to PM or send him an Email

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84 300D, 82 Volvo 244Gl Diesel

They ended up replacing the pump

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1984 190d 2.2 Greasecar Kit. Running Wvo for 25K
1993 300D 2.5T Black on Black. Soon to be Greasy!

Thanks.

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84 300D, 82 Volvo 244Gl Diesel

This is rough to read…I am dealing with cylinders 3/4 on an OM601 that has no fuel flow out of the delivery valve holders after a DV re-seal attempt. It ran before…now only 1/2 are receiving fuel flow. When the DV’s are off, fuel will seep out of the holes due to gravity so it seems like it is getting fuel. But just not building pressure.

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1982 300TDT
1991 190D
2022 Metris

You might try lapping the delivery valve pieces together using Diseasel300's method: (post #116) https://www.peachparts.com/shopforum/diesel-discussion/363700-delivery-valve-internal-leak-cause-nailing-yes-no-maybe-8.html

I tried this so far on my #6 DV. It seems to have made things smoother, although I did not verify exactly which cylinders were the problem ones (as I have nailing coming from multiple cylinders) and am planning to eventually do them all.

Anyways, I did notice when mounting the plunger half of the delivery valve in a drill chuck it spun with bit of a wobble. Maybe the drill's spindle wasn't true or just not enough meat on DV plunger to grab onto with the chuck. Next time I may try sticking the end of the plunger piece into to a short cut-off section of vacuum hose and putting the other end of the hose in the drill to mitigate wobbling while lapping.

I would also try to work on one delivery valve at a time. Remove line at both ends and the mount / plastic holders to free up that one line. Start and run the engine between work on each valve otherwise you'll spend a lot of time charging battery between attempts to reprime all fuel lines and start the engine. If you do get in that situation, crank w/ glow plug relay disconnected until fuel starts coming out of # 6, 5, and then #4 lines. Then tighten those three lines, reconnect glow plug relay, have someone hold pedal to floor and crank until it starts to run (very roughly) and then tighten #'s 3, 2, and 1. Might have to crack each line one at a time again to get all bubbles out once it starts running.

Hopefully this is helpful. The lapping apparently is supposed to help renew the seal between the delivery valve plunger with the barrel so it can hold pressure for the injection event. It could be you aren't able to hold pressure from corrosion, buildup or foreign object in DV. Also, of course, verify they were oriented right on install and that correct torque sequence for the DV holder was followed.

I will be tackling this issue this spring i think, i have 3 dvs not outputting...

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John HAUL AWAY, OR CRUSHED CARS!!! HELP ME keep the cars out of the crusher! A/C Thread
"as I ride with my a/c on... I have fond memories of sweaty oily saturdays and spewing R12 into the air. THANKS for all you do!

My drivers:
1987 190D 2.5Turbo
1987 190D 2.5Turbo
1987 190D 2.5-5SPEED!!!

1987 300TD
1987 300TD
1994GMC 2500 6.5Turbo truck... I had to put the ladder somewhere!

On the first DV seal job I ever performed I put the "barrel" (not sure proper term) with the slot on the side in incorrectly. I did not realize there was a pin that the slot had to fit over. I ended up damaging the pin causing rough idle and smoking issues. I removed the pump and got it to a Bosch shop where they were able to repair it by supposedly pushing what was left of the pin a little further out.

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Jim

Interesting. I am definitely worried I may have messed with something below the delivery valve. I have lapped the two problem DV's at the suggestion of a local Bosch pump shop. I am going to open up the side plate of the IP and inspect it again to see if I can see anything out of place. I can get fuel to squirt out of the DV holder when the DV holder is finger-tight, not torqued down. So fuel flow into the DV is not a problem. It's almost as if when torqued down there is a pressure problem or blockage. But I know its completely clean and clear.

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1982 300TDT
1991 190D
2022 Metris

There is other threads with pictures of the pins and the slots on the barrels. It is a common issue.

If people pull up on the deliver valve the barrel cumes up with it and if it turns it does not line up with the pin.

I mentioned this in other threads. Before you unscrew the deliver valve holder that one you need the splined socket for you measure from the top to the bottom and record that.
When you put it back together you screw it in by hand as far as it will go and compare that to your measurement. It should be really close to your measurement.

If the barrel has rotated and your toque it down frequently what happens is it pushes the alinement pin out and the barrel is not aliened. That normally does not damage anything.

A picture of the barrel slot in post 4.
http://www.peachparts.com/shopforum/diesel-discussion/360250-220d-injection-pump.html

A different picture in post number 4 in the below thread. What the picture is showing is the cover off of the side of the fuel injection pump. If you look closely, you will see a line of numbs on the inside top of the opening. And you will see the aliment pins. All of the alignment pins should be at a similar depth. If you see one that is sticking out more that is the pin that got pushed out of the housing.

http://www.peachparts.com/shopforum/diesel-discussion/317678-replaced-delivery-valve-seals-w124-300d.html

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84 300D, 82 Volvo 244Gl Diesel