Thanks to all whose posts helped. Just finished all six delivery valves -- installing new copper seals (keep pressurized fuel in) and o-rings (keep out air and dirt). Taking the intake manifold off was a real ordeal -- it was a #5 allen bolt beneath the arm supporting and connecting the intake. I rearranged the collar clamp (both a 10mm bolt and lock washer) so that I could reach them more easily in the future. They were oriented up and down and really not readily accessible, to say the least!
If it weren't for searching online (someone here referred me to another site and someone had just asked the question this AM about the intake man. -- he also had a 99 E300 Turbodiesel (I have been informed that the nomenclature is E300DT if it were TD it would designate a wagon which mine is not) and the pics and verbiage really helped -- just in time. It was still not so easy -- you drop a bolt, you need another socket (store trip and I did three of those), water, as it was pretty warm here today.
Ron, aka WHunter on MB shop forum was really helpful, except my fuel lines didn't arrive today (not his fault, the shipper, who else, UPS). I broke one and had to go to the local dealer and buy one for 16 bucks -- bot a refund of 8 bucks as I returned the fiber manifold gasket as mine uses the metal one. They didn't know last week when I bought 'em so I took both. Now, when the new fuel lines come from Ron's outfit, I'll return the appropriate one to the dealer.
The rest of the hoses look ok and my test drive showed no leaks. It took about a dozen cranks to start up but I cheated and after about nine starts, I filled the prefilter chamber to the top with diesel and she started up on third attempt. Battery charger at boat and that would have been another trip if I killed the batty.
It did rumble and idle terribly on first start up -- two injector hoses were loose at the injectors -- thought I checked them but. Suggestion--thanks for tip to use 14mm flare wrench -- also need one which is bent. I didn't even loosen the back two injectors, just the line tie in. I don't think it's a good idea to bend those lines, just loosen/take them off in pairs. The banjo locks on the delivery valves, do an alternating lock step on one another so you just can't do two and finish them completely. Just a small point to add.
It's done!!! Now I want to see my mileage climb from 22-23 around town to the upper twenties. Ron had said that the air leaks from the delivery valves would screw up the fuel metering. Oh, yeah, the first delivery valve where I noticed the leak had a split o-ring and it was displaced from the proper groove. Two others had little nicks but weren't leaking yet. Whoever said he had an awful mess of bits of o-ring had given me cause for concern -- but it wasn't that bad and no need to flush out fuel thru injector hoses (what a mess that would be)
Thanks to all -- accomplished the job without the manual thanks to the online info. Later, Rick
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