I can not get fuel from the delivery valve port closest to the front of vehicle. All the other injectors are getting fuel. Anyone have any ideas? I pulled the delivery valve and there was some crap in there. I cleaned it out the best I could from the top. Is there a way to check to see that the rack is moving properly? Is there a better way to clean out the delivery valve port?

Thanks

If anyone needs me to explain the situation better/further please let me know.

Thanks

ttt

Also I searched and found one similar issue that ended up being an unrelated problem and not my problem.

nobody has any ideas? well if I find a solution I will post up and let you know whats up> for tech sake.

If your IP has a flat metal cover on the side of the IP held on with screws you can remove this cover and look inside at the Fuel Rack. However, if you are gettin fuel out of the other ones it is not the Rack itself that is causing the problem.

You did not say where the crud might have come from assuming there were the proper filters on the Engine.
If crud went through the IP it is possible that the port on the side of the #1 Element/Plunger and Barrel is plugged and not letting the fuel from the Fuel Supply Pump into the Element. However, this is not a part of IP that people othere than Techs that work in a Fuel Injection Shop would pull out and mess with. On Member who had the same problem wanted to back flush it with air pressure to unclog the Hole; but I do not know if he did so.
If you want to try air pressure I suggest that it be under 20 psi.

Another possible is that the Element Plunger is stuck in the upward position and not going down.
Also sometimes the Element Plunger return springs can break (If your IP has a cover and it can be removed you can look at the springs).

I cannot make any more suggestions as I do not know what your IP looks like as I only have an older Car. Example: the IP on my 84 300D is a different model and has no removable cover on the side; I cannot look at the rack or Plunger return springs.

In the last 8 months there has been at least 3 threads with a similar problem. I would do a search for them

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84 300D, 82 Volvo 244Gl Diesel

Also how about a better history of what happend.
Is this an Engine that has been sitting a long time and you are trying to get going or was this a vehicle you were driving and suddenly had a problem with?

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84 300D, 82 Volvo 244Gl Diesel

This is a daily driver. I had a very loud knocking that I believe was air or lack of fuel. I did delivery valve seals and now I have no fuel coming from the #1 port. I now believe this has been the problem the whole time. Now that all the other delivery valves are sealed it has made the #1 stick out. Before I did delivery valve seals I was getting some fuel from the #1 port. Now there is none so I now have a completely dead cylinder.

Is there a specific orientation for the valve below the pressure valve carrier? Other than the fact that it only seams to go in one way? Maybe this is what is messed up?

See post #1 PDF for orientation of all the pieces and parts.
http://www.peachparts.com/shopforum/showthread.php?t=173991

The crush washer will often be found up inside the pressure valve holder.

Are you sure the spring remained in position when you reinstalled everything? A dab of white grease will help glue it in place while you screw it down.

Certain the new oring didn't get nicked or pinched?

Torqued to 35NM?

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Terry Allison
N. Calif. & Boca Chica, Panama

09' E320 Bluetec 77k (USA)
09' Hyundai Santa Fe Diesel 48k (S.A.)

There is a plunger? under the pressure valve carrier that I removed. Is there a specific orientation for this? Does anyone ever removed this plunger other than inj. repair shops?

See 7G and notation to "pay attention to installed position".

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Terry Allison
N. Calif. & Boca Chica, Panama

09' E320 Bluetec 77k (USA)
09' Hyundai Santa Fe Diesel 48k (S.A.)

I installed everything in the PDF picture installed in the correct orientation. Underneath all that there is another valve or plunger. I removed that. Do you know if there is a proper orientation for that? It is not in the PDF picture.

Thanks.

I know there are a lot of threads on the proper delivery valve seal replacement procedures and I have read them. I cannot find much on what to do if there is a problem such as I am having.

I really need to find out what the plunger under the pressure valve carrier is and if there is a specific orientation. The #1 port is the only one I took this plunger out of and the only one that is not delivering fuel. It has to be part of the cause.

Thanks Again

I always recommend leaving the 7K and 7G alone to avoid probelms. Is no reason to remove them when replacing the seal and crush washer. You went even deeper......See what D911 says but I suspect it is time to visit a Bosch Service Center and have it recalibrated on their bench.

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Terry Allison
N. Calif. & Boca Chica, Panama

09' E320 Bluetec 77k (USA)
09' Hyundai Santa Fe Diesel 48k (S.A.)

The Plunger is the inner part and the Barrel is the outer part.
The Barrels most often have an orientation slot milled into the side that lines up with a Pin in the side of the IP housing. You cannot see the slot looking down into the IP with the Pressure Valve removed.

If the Barrel rides above the orientation pin and is rotated it will not work properly (there is a thread where this happend to a member within in the last 2 weeks). If the above happens when you install the Deliver Valve Holder; the Delivery Valve Holder will not go back in as far as the rest of them. If you torque the Dlivery Valve Holder down with the Barrel not aligned with the Pin in the IP housing it is also possible to break the pin off.
For referance take a look at the 1st diagram at this site:
http://www.detali.ru/cat/oem_mb2.asp?TP=1&F=124133&M=603%2E960&GA=722%2E357&CT=M&cat=503&SID=07&SGR=045&SGN=01

#23 is the listed as the Pump Element (what I call a plunger and barrel). The Pump Element is a matched set of 2 pieces. The outer, upper, fat portion being the barrel; the part with the orientation slot.
The lower portion sticking out of the bottom that is sort of T shaped is the Plunger. The Plunger moves up and down and rotates inside of the Barrel which is stationary.
If you pulled the Plunger out (you have to take the compete Element out to pull the Plunger out) you will find it also has an orientation mark. However I doubt if this is out of alignment and I believe is held in place by the return spring and spring retainer.
Item #29 is listed as a Clamping Piece. This connects the plunger to the Fuel Rack by way of Item #26 Sleeve.
Not often but some times the secew that holds Item #29d becomes loose and the Clamping Piece slides free on the Fuel Rack. The Clamping Piece is how they adjust the Fuel Delivery setting on the IP so if it moves freely around your fuel setting on that Element will be off.
You can view the clamping Pieces by removing the flat metal cover with 6 between the Fuel Supply Pump and the top of the IP housing.

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84 300D, 82 Volvo 244Gl Diesel

One more thing. After reviewing some receipts from the PO I noticed a quote for delivery valve seals. I have read numerous threads that mention distorting the pump housing if the delivery valve is not torqued properly. How would I know if the housing is distorted? I did notice when I was removing the delivery valves that they were not all equally tight. A couple were pretty tight and some not so tight. Just trying to see if that could be part of the equation.

After I figure that out my plan is to replace the crush washer and oring in both the #1 and #2 since I took them both out to inspect and compare. I am also going to prime both with diesel.

Thanks for all the help. I realize this subject has been beaten to death. I just couldn't find much on what to do if you believe you have done everything properly yet you are having problems. I will be sure to add any new tech that may come out of this situation.

I do not think the subject has been beaten to death as there is not a clear answer when the problem goes beyond air trapped in the system or and O-ring problem; and it is a problem that has happened to several Members.
It is just very hard to determine what is going on in this case unless you are there.

As far as the distorting of the IP housing; it is made of Aluminum and too much torque can displace/crack the metal. How much torque it takes to do damage is hard to guess.
All you can do is do a visual inspection and look at the housing threads and see if it looks like they have been distorted; not much you can do after that.
You might want to post what State and City you live in. Maybe one of the Members would consider taking a look.

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84 300D, 82 Volvo 244Gl Diesel