I have a fuel leak, it looks like it is coming from the top of injector pump. Look at my pictures and tell me what you think I need to get. Thanks.

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IP Delivery Valve seals and O-Rings, if you do a search you will find a huge amount of information regarding the fix! Good Luck!

Thankyou. So I need 5 delivery valve o-ring and 5 pressure valve seals? Is that all? Any special tools?

There is a special splined tool for removal.

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Grumpy Old Diesel Owners Club group

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1967 230-6 auto parts car. rust bucket.
1980 300D now parts car 800k miles
1984 300D 500k miles
1987 250td 160k miles English import
2001 jeep turbo diesel 130k miles
1998 jeep tdi ~ followed me home. Needs a turbo.
1968 Ford F750 truck. 6-354 diesel conversion.
Other toys ~J.D.,Cat & GM ~ mainly earth moving

Can I get it here on this site? What is it called? Thanks.

Yeah there is a special tool MB # 617 589 01 09 00 a serrated socket that can be bought here, the dealer and online, or rented. You'll also need a T30 Torx tool to remove the keepers, and a torque wrench particularly if you replace the copper washers.

Do I need to remove the intake to do this job?

I didn't remove the intake when I did the job on my higher mileage '91 but it would have been easier if I had.

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Greg

Current
2005 E320 CDI (50k) W211 with OM648
1999 E300D Turbo (133k) W210 with OM606.962
1997 E300D NA (170k) W210 with OM606.912
1991 300D 2.5 Turbo (199k) W124 with OM602
1990 300D 2.5 Turbo (170k) W124 with OM602

I am sorry for all the questions but what are the chances that the pressure valve seals are bad? I think it is the delivery valve o ring, or should I replace the pressure valve seals while I am there?

If the O-ring is bad you need to replace the copper washers as well, the instructions are around here somewhere. I just did three on my IP, solved my problem completely. I should do the other three but I could only get to the first three w/o removing intake on the 6 cylinder, and since that stopped the leak I wasn't motivated to open up the other three...yet.

It's a really messy job, once the valves are removed the pump likes to purge off fuel through the valve orifice, keep lots of rags around! Do one at a time!

my .02

steve a

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Steve A
92 W140 OM603
97 VW Jetta TDI
90 Passat variant TDI 6 speed MT
94 Chevy K1500 6.5TD
05 E320 CDI
+ others

Injection Pump Fuel Leak Fix on the 1991 W124 300D Turbo 2.5 (OM602.962)

You can work with the intake on, you'll just need to move the injector lines sufficiently and have appropriate socket extensions (I had two articulated joints, more necessary near the rear).

Make sure everything is VERY clean. Take your time, do the research beforehand (it's here), clean, cover with rags and you should be good to go.

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1982 240D, sold 9/17/2008
1987 300D TurboW124.133 - 603.960, 722.317 - Smoke Silver Metallic / Medium Red (702/177), acquired 8/15/2009
262,715 and counting

Thankyou to everyone!!

Take pics as you go, and good luck. Great info available for you here as mentioned!

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Jimmy L.
'05 Acura TL 6MT
2001 ML430 My Spare

Gone:
'95 E300 188K "Batmobile" Texas Unfriendly Black
'85 300TD 235K "The Wagon" Texas Friendly White
'80 240D 154K "China" Scar engine installed
'81 300TD 240K "Smash"
'80 240D 230K "The Squash"
'81 240D 293K"Scar" Rear ended harder than Elton John

+1

I ended up bending some injector lines in the process when I didn't remove the intake and it was harder to get a torque wrench on them as well.

But....it worked

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1993 W124 300D
-297K on the clock as I type this.

Absolutely!

If you don't you will compress the existing seals too much when you torque to specifications.

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1993 W124 300D
-297K on the clock as I type this.