fuel leaking from high pressure pump - Mercedes-Benz Forum
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post #1 of 13 (permalink) Old 02-24-2007, 03:24 PM Thread Starter
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Date registered: Feb 2007
Vehicle: sprinter 208 cdi 2002
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fuel leaking from high pressure pump

I thought i must share this experience with you all.
i recently had a problem on my 2002 sprinter 208 cdi. it developed a fuel leak when cold from the top of the pump as soon as the engine reached opperating temp this leak would disapear i put up with this for a while as it didnt leak for long but as the weather got colder so the leak lasted that bit longer till eventually it just got to the point that it never stopped and as all problems develop when you are miles from home, so i had to do the unspeakable thing i rang the local mercdads well that was a shock they wanted £1000 inc vat to repair it. Not on your life so the van got parked at the hotel for the week and i got a lift with one of the lads on site i rang my local mercdads and got a similar reply, but i could do the job myself when i got back to my tool kit for a mere £350 still not happy i decided to go to the local dealership late at night when i got back and spoke to one of the fitters youngish chap loads more help told me that bosch had talked about releasing a seal kit for that pump as it seams to be a common prob but he had never heard of anyone getting a kit let alone doing it them selves but never the less he grabed an old pump off the bench and promptly whipped one of the heads off and showed me the ofending seal looked real easy
now im like even more determined not to spend £350 on an o ring with what looked like a nipple shape at the top and so the hunt started and yes we did find a seal kit a genuine bosch seal kit and 3 hours later pump is back on and yes it was still leaking but worse so i must have done something wrong? you ask yourself and you would be right i did what i did was tighten the head bolts up uneavenly so the pump was off again and this time i did it right and here i am 1 week later and still no leaks. heres the moral if it dont look dificult then it probable isnt if merc says it is expensive it might not have to be.
If anyone else has this prob and needs any advice please contact me.

Last edited by rifletech; 02-24-2007 at 03:27 PM.
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post #2 of 13 (permalink) Old 02-28-2007, 02:34 PM
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I had a simalar prob with my 316cdi, but opted for the quick fix, bought a new pump and fitted it on the side of the road took about an hour and the pump cost £135+vat.
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post #3 of 13 (permalink) Old 03-01-2007, 09:42 AM Thread Starter
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I think i would have gone down that road for that money where did you find a pump that cheep it cost me less than £30 in the end but with the risk of it not lasting long but since i posted the first thread i towed a trailer 200miles loaded a 1964 austin gypsy fire engine on and drove it straight back no probs no leaks so looks like its worked ok
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post #4 of 13 (permalink) Old 03-07-2007, 09:11 PM
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I have a 312d with a leaky pump would your advice work for that model also and where can I get this Bosch kit. thanks
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post #5 of 13 (permalink) Old 03-11-2007, 04:44 PM Thread Starter
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Originally Posted by kenr
I have a 312d with a leaky pump would your advice work for that model also and where can I get this Bosch kit. thanks
Sorry for the delay in getting back to you i work for the MOD and have been away in answer to your question if your fuel system is common rail and you have the high pressure pump mounted on the front of your engine then yes it should what you will need off your pump is the part number off the left hand side of the pump it is a bit awkward to see i used my phone to take a picture then blew it up on pc as for where you can get it from in your area i'm not sure i got mine from cheltenham diesel in cheltenham they are a local diesel centre it cost me £14 something.
To do the job i took the slam panel off disconected the intercooler hoses both sides pulled rad forward took the fan cowel off took the fan blade off and then the serpentine belt and the you can get to the 3 torx bolts that hold the pump on you should also replace the 2 clips that hold the 2 fuel lines back to the engine as they break when you unclip them unless you are really lucky or use a small tie wrap but make sure you fix these pipes back after as they will foul on the serpentine belt and then you will have a leak!! it will probably take about 3 hours inc resealing the pump
the seals i replaced are the (on each head) the 2 blue o-rings 2 white nylon
o-rings these are located one each on the head and one each on the main block beneath a small hollow pin that will either be on the head or block depending which side it stays in when you separate it and a very small metal ring this a little awkward and the main head seal which i held in place with a VERY SMALL smear of grease then tighten the head bolts up VERY evenly i cannot stress this enough i did it about 10 degrees each at a time as the head does not mate on a flat surface it mates against the round disk in the middle so if you tighten one bolt up first it will tip the head and then wont seal i know i did it and had to take the pump off again so if you tighten them up evenly you will have learned from my mistake and just remember to keep it all very clean
I hope this helps if you need any more help let me know

Rob
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post #6 of 13 (permalink) Old 03-12-2008, 12:36 PM
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Hi All
No need to remove the pump at all. If you loosen the 2 bolts on the side of the pump you can gently rock the pump forwards with a screwdriver. Place a spline in the back left bolt and unwind just until it can move no more. Then move the pump forwards slightly and unwind the bolt more and it will pop out.
post #7 of 13 (permalink) Old 06-19-2008, 12:39 PM
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hi there same thing but 313 cdi ,took pump in to diesel specialist,i showed him the seal that was split,he sorted me out the seals then and there. It must be a common problem. I found it took longer to get the pump off, as other pumps in the way,than to mend it .A big prob i had was undoing the hex bolts on the top,they where so tight the hex started to slip,even though i tightened them first and tapped the tops .I had to knock them round with a punch !!
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post #8 of 13 (permalink) Old 02-10-2009, 08:49 AM
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thanks for the reply. unfortunatly I'm still dealing with the leaky pump. I was wondering with this Bosch replacment seal kit if there is a place in your area I can order on line. Not just for that particular item but any 312d sprinter stuff. The reason is that I live in Japan and there is only a handfull of these vehicles here so there are no shops here that deal with this particular vehicle. I really do appeciate any help and advice I can get. Ken
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post #9 of 13 (permalink) Old 02-10-2009, 08:51 AM
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thanks for the reply Do you know if I can order online from this shop?
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post #10 of 13 (permalink) Old 02-10-2009, 02:25 PM
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Hi ken, I ordered the part as mentioned at the top of the thread from Cheltenham diesel. They told me there were two possibilities, I opened up the pump, told them what I could see and he got it straight away. All done over the phone as I am in Manchester and I got the seal kit the next day in the post. Great service.

I'm sure if you ring them they will assist you. If the call will be too expensive, then set up a skype accont, its free to landlines. If you pay the postage, cant see any problems in them getting the required kit to you.

Hope it helps

James
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