After doing my delivery valve replacement it seems they are leaking again and I am unsure as to why. I bought the copper seals and O-rings from pelican parts so I cannot imagine why either would be the wrong size. The top of the IP was very thoroughly cleaned before putting the valves back together so I think assuming any kind of dirt causing this can be eliminated. All the O-rings were dabbed with diesel fuel before inserting and all were torqued to 35Nm per procedures. Initially there was no leak but when i went to check oil the other day I noticed the IP was completely wet and seemed to be worse than before. Where could my error be? Upon initial O-ring replacement I thought the originals seemed thicker but just put this off as them being crushed down over the year. The only thing I can assume from this is that the O-rings were inadequate for one reason or another.

Clean everything off a spray it down with brake cleaner so it is nice and dry. Start the Engine and make sure the leak is coming up from the Pump and the delivery valves and not leaking down from the Hard Lines and their Nuts.

Also find out if it is leaking from all or only one area.

If the leak is from all of the O-rings I would contact Pelican Parts and see what they have to say. It could be they switched suppliers and the suppler is not giving the correct O-rings.

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84 300D, 82 Volvo 244Gl Diesel

I had the same problem, I can't recall exactly why as it's been about 4 years, but I do remember i slightly tore an o-ring on installation causing it to leak like a sieve.

Diesel911, I put a light underneath the Intake Manifold and looked around for a good while. I believe I can safely say its the Delivery valves. I have not dried each valve and checked to see if each was leaking but will attempt this today.

Thatguy, I believe a o-ring tear could be a high possibility now that you say it. When I installed the O-rings everything was dry and i used my finger to dab on diesel around the rings leaving the inner diameter dry. It seems likely inadequate lubrication could certainly cause one to tear upon install.

I use generic STP on O-rings I get at K-mart or Wal-Mart.

It works great but if you have a leak because the STP is thick it can take sometime for a leak to show up.

Is the Engine runnin OK even with the leaks?

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84 300D, 82 Volvo 244Gl Diesel