There’s a different gasket for aluminum side panel vs stamped side panel.

Sixto
E320s sedannand wagon
02 C320 wagon

Bullocks! How can I tell the difference between the 2 styles Sixto? I can try to take a picture tomorrow.?.

Thank You in Advance!

g

__________________
1987 300 TD - Kraut
1987 300 D - Hans

Also, another quick update.

I connected the battery today. Cranked the engine. Cracked the line at one of the injectors and had fuel and bubbles. I have cracked the lines in the past and it seemed as though the spurting was "weaker".

I will post more as I have more.

Thank You All Again!

g

__________________
1987 300 TD - Kraut
1987 300 D - Hans

This is a stamped cover -



An aluminum cover is a thick silver slab (602 IP shown) -



Sixto
98 E320s sedan and wagon
02 C320 wagon

My apologies Sixto. I am referring to the lift pump gasket. :-)

I believe I have the aluminum side panel though. Would you happen to know the gasket part number? :-)

Thank You!!!
g

__________________
1987 300 TD - Kraut
1987 300 D - Hans

I posted all the 603 IP gasket part numbers here a out 10 years ago or whenever I had my SDL. I can’t find the post though.

Sixto
98 E320s sedan and wagon
02 C320 wagon

So I added 10 gallons of fuel this past week. 5 gallons last weekend and she would not start. I added 5 more gallons Friday morning and decided to try starting on Friday evening. After approximately 30 seconds of cranking, she started and made it home.

To that end I believe I am definitely search for a fuel supply problem. I will schedule some time to drop the filter in the tank and possibly power wash the tank this spring.

I am going to replace the o-rings in the lift pump (Thank You Diseaseal300). I am guessing they have never been changed. At least not in the past 9 years I have owned the girl.

The clear fuel filter is dirty but I can still see into it. The can filter is at least 3 years old. I will get these changed.

Interestingly, thanks to this issue, I have discovered that my glow plug light on the dash is not illuminating. I am guessing it happened during the summer and I did not notice it when the temperatures were consistently >90 degrees. :-/ I got into the habit of waiting until the buzzer stopped (in honor of Rudolph) and not checking the light. Glow plug relay has been added to my checklist. The glow plugs are less than 2 years old.

I thought I would share some "good" news and share my next direction. Any advice is always welcome! :-)

Thank You All!!!

g

__________________
1987 300 TD - Kraut
1987 300 D - Hans

If I had to guess, its the fuel tank flow problem - time for all filters and that screen on the tank. GP problems aren't too much of an issue in LV though they hasten starting, it will happen without them - I wouldn't expend energy on the GP relay until you know there is no power to the GP themselves.

__________________
DS
2010 CL550 - Heaven help me but it's beautiful
87 300D a labor of love
11 GLK 350 So far, so good
08 E350 4matic, Love it.
99 E320 too rusted, sold
87 260E Donated to Newgate School
www.Newgateschool.org - check it out.
12 Ford Escape, sold, forgotten
87 300D, sold, what a mistake
06 Passat 2.0T, PITA, sold

Las Vegas NV

I'd venture to say it's the poppet valves on the top of the IP, leading to the injector lines. I've heard them called o rings, but they're really look like a metal washer/disk and spring. Cheap to fix. If they leak and you have any air at all, the engine won't start since the air compresses on the injection stroke and leaks right past the valves at the end of the stroke preventing any actual fuel delivery. May also be called fuel delivery valves.

Latest updates:

* I have replaced the O-rings in the lift pump. Although there it held suction and blew pressure, the smaller O-rings were hard and brittle! However, this did not fix the problem.

* So we dropped to the 30 degree mark early last week. I believe my glow plug relay may need a new fuse. Is the relay one of the boxes behind the battery? I have been trying to find a post with a picture of its location but have come up empty handed...

* I have a new clear filter and a new screw-on filter ordered and should arrive on Monday. I may grab a new clear filter from AutoZone tomorrow just to swap it.

Bernhardt - I have replaced the o-rings on the top of the Injection Pump. They were falling apart. I put in o-new rings but they did not seem to fix the problem either. :-( I am thinking about re-torquing them to make sure I applied the correct amount of torque to each. I did follow the tighten, release, tighten, release, tighten recommendations.

DLSSmith - Thank you for your insight! I too was thinking about a fuel flow issue. Alas, even with an almost full tank, she still cranks a bunch before starting. That being said, I am hoping to drop the tank this spring and give it a good cleaning.

I will continue to update as time permits. Thank You all for sharing your knowledge!!!

g

__________________
1987 300 TD - Kraut
1987 300 D - Hans

Take the fuel tank out of the equation. Put some Diesel fuel or Diesel Purge in a quart jar and dip the hose to the small filter in the jar below the fuel level. Also dip the big return hose in the jar.

Does that allow the engine to start more quickly?

After you replace the delivery valve o-rings and washers, crack each fuel line at the injectors. Crank for 10 seconds. Tighten the lines that are wet. Crank for another 10 seconds. Tighten the next lines that are wet. IIRC at that point the engine catches and bleeds itself the rest of the way. If not, umm... yeah, something’s amiss :/

There are posts in the archives of situations in which fuel never gets to the injectors, fuel flows to the front 3 or rear 3 injectors but not the others, stop lever stays down while cranking, etc. Sounds like someone should make a sticky with a comprehensive checklist.

Sixto
98 E320s sedan and wagon
02 C320 wagon