[teddyd49]

I have sourced the part of the engine that is leaking onto the ground having believed that it was an oil leak. It appears to be coming from the injector pump and the area directly below this pumps in wet at all times (leaking fuel).

I have scoured the internet parts sellers to try to find a "re-seal" kit for this pump but have not found anything. I am told that this is a Bosch part and, as such, needs to be purchased directly from Bosch or an authorized dealer but I don't think this is going to work having contacted several service groups in the area.

Does anyone have a clue as to how I might proceed to fix this problem without going to a dealership to have my face ripped off? Thanks.:surrender::

 

[300Dman]

I have sourced the part of the engine that is leaking onto the ground having believed that it was an oil leak. It appears to be coming from the injector pump and the area directly below this pumps in wet at all times (leaking fuel).

I have scoured the internet parts sellers to try to find a "re-seal" kit for this pump but have not found anything. I am told that this is a Bosch part and, as such, needs to be purchased directly from Bosch or an authorized dealer but I don't think this is going to work having contacted several service groups in the area.

Does anyone have a clue as to how I might proceed to fix this problem without going to a dealership to have my face ripped off? Thanks.:surrender::

There is no commly sold kits for the Fuel Injection Pump because they seldom cause any issues and there is parts of the Fuel Injection Pump that if you move some parts around changes the calibration of the Fuel Injection Pump.

It was back in 1975-1980 but I used to work in a Fuel Injection Shop.
I could help more easily if you just said where the Fuel Injection Pump was leaking.
Also do you know if you have an MW or M type Fuel Injection pump.
The M Type takes a special Socket to remove the Delivery Valve Holders.

If it is an Oil Leak coming from the Bottom of the Fuel Injection Pump there is a Pan on the Bottom that is sealed with a fat Square Crossectioned O-ring. You can buy the O-ring as a seperate part from Mercedes or Bosch or simply remove the Pan and carefully Apply Silicon Sealant.
However, the Screws on mine were on really tight and are made for a Blade Screwdriver. That makes the job hard to do with the Fuel Injection Pump on the Engine.

The Throttle Shaft O-rings can be replaced; another leak area.

Where the Fuel Injection pump bolts to the Block has a thin paper Gasket. That would not come in a Gasket kit and is a separate order. The Fuel Injection Pump has to come off to change it.
When I changed mine I did not like how thin the Stock Gaske is and used it as a Template and made another gasket with thicker Gasket Paper.

There is also a Plastic Oil Feed Line that goes from the Block to the Fuel Injection pump. That can be replaced as a separate part and you need 4 copper crush washers. The plastic can get old an Crack.

The M type Fuel Injection Pumps have a Cover on the side of the Pump that has a Gasket that can Leak Oil. Another item that shows as a separate part.

The most common Oil Leak spots are the Block to Pump Gasket, the Bottom Pan Gasket, The M Pump Side Cover with the Throttle Shaft O-rings last.

Fuel leaks:
If you mess with the 13mm Nuts on each side of the Fuel Outlets/Delivery Valve Holders you will change the amout of Fuel each one of those Elements pust out. So the Elements are not something to mess with unless your absolutly have to as they are set on an expensive Calibrating Machine.

With the exception of the above the other areas that might leak Fuel can be taken care of with out a whole kit.
The Delivery Valve Crush Washers can be bought each.

However, if you insist on a complete kit write down the Numbers on little Plate on the Pump and take it to a Bosch Fuel Injection Shop and ask them the Cost and Availability of a gasket kit.

In the Mercedes parts catalog they show a Gasket Kit for the Fuel Injection Pump. I don't know how complete it is.

You can get a Valve Kit for the Fuel Supply/Lift Pump; it has 2 Valves, 2 Springs and 2 Copper Crush Washers.


Another person with a leaking Fuel Injection Pump.
http://www.benzworld.org/forums/w123-e-ce-d-cd-td/1673863-diesel-injector-pump-leaking.html

 

[teddyd49]

OUTSTANDING feedback on the problem from soup to nuts....thank you....will try to figure this one out with my pal who is a mechanic and see if we can't get to bottom of this. It appears that diesel fuel is leaking and NOT oil. I don't know if this narrows down the usual suspects. If so, please let me know what to throw out as an option. Cheers!

 

[teddyd49]

Will also try to let you know WHERE the leak is coming from on the injector. Will not be able to get to this for several days but will get back to you. Thanks.

 

[300Dman]

When you find the leaking area see if you can take a pic and Post it.

 

[teddyd49]

Will do...thanks....

 

[teddyd49]

Photo of Leaking Area of Injector Pump Area

These are not the greatest pictures as they were taken while car was up on jacks (not a lift) using a phone camera and a flash light but they might or might not help you with solving this mystery (if you are still game).

We still have not been able to get back to this leak yet as other things have occupied my mechanic pal who is doing construction work as his "real" job for the time being. But hope to get back to this before too long.

Once again, thanks for your input to-date. It still looks like there is fuel rather than oil leaking from this area at present....a slow leak but a steady leak that needs to be taken care of....

 

[mrspaz]

These are all photos of your A/C compressor. Is the fuel ending up dripping down on to the compressor somehow?

The compressor is situated a bit forward of the injection pump, so if you continually find it wet with fuel I would suspect the spin-on fuel filter or one of the lines that runs to that filter, since it is situated almost directly above where the A/C compressor is mounted.

Check to make sure the spin-on filter is screwed in securely and fuel isn't leaking around the edge. Also check the small braided fuel return hose that runs from the injectors to the spin-on filter housing. Those would be the two most likely spots for a leak in that vicinity.

 

[teddyd49]

thanks...will do.....

 

[300Dman]

Since you sent pics of the AC compressor and not the Fuel Injectin Pump here is a pic of the Fuel Injection pump; off of the Engine.

Also depending on what year you have the Central Bolt in your Fue Filter Housing will have an O-ring on the Bottom and an Aluminum or Copper Washer at the top or the Central bolt will have a O-ring at the Bottom and an other O-ring at the top

 

[teddyd49]

thanks...pic taken by mechanic friend so I'm not certain he was shooting the place where the leak is evident or he was shooting the compressor....A/C also being worked on in this car....compressor needs replacement...have acquired a new one...awaiting mechanic availability.... I will share this pic and input from you with him...thanks again.

 

[Ramanna]

I too had this problem of disel fuel leak from the injector on my 1984, 240D specially after the engine was shut off. I took it to Bosch certified workshop. The guy repalced 4+1 'O' rings and pressure tested the unit. The problem was solved. I felt it was not a DYI job. Glad Bosch has a large presence in India. Not only this the guy ran a compression test on all the cylinders and certified the engine. He told me he has to report the findings to Bosch for their on going research. The milage certainly improved after all this.

 

[300Dman]

I too had this problem of disel fuel leak from the injector on my 1984, 240D specially after the engine was shut off. I took it to Bosch certified workshop. The guy repalced 4+1 'O' rings and pressure tested the unit. The problem was solved. I felt it was not a DYI job. Glad Bosch has a large presence in India. Not only this the guy ran a compression test on all the cylinders and certified the engine. He told me he has to report the findings to Bosch for their on going research. The milage certainly improved after all this.

There are Forum Members who have changed their own O-rings and there are Instructions posted on some of the Forums.

There are 2 types of Fuel Injection pumps. The M Type Pumps that have the O-rings have Delivery Valve Holders that you need a special Splined Socket to remove.

The MW type Pumps have Delivery Valve Holders that you can use a regular Deep socket on has no O-rings in the Delivery Valve Holders.

Here in the US labor rates are higher and some Fuel Injection Shops don't liked to do what they consider patch-up work. The prefer to rebuild.

Part of the reason for that is issues with a warranty.
They do they change the Delivery Valve O-rings and when the Customer installs the Pump it leaks somewhere else on the Pump and the Customer is going to say it was not leaking in the other spot before you touched the Pump.

Another issue is that the Customer may install the Pump improperly and blame them.
You could say that the same is true if the rebuilt the pump but actually a person who spends 1-2 thousand dollars on a rebuild is more likely to install the pump correctly they someone trying to save a Penny. The attitude of the Customer is different.

Where I worked we subcontracted Electrical work to another Shop.
That Guy had all kinds of trouble with is "Budget Customers".
He raised is Hourly Rate to the extent that it drove away the Budget Customers and His Customer issues decreased dramatically and He had less trouble getting paid.

 

[teddyd49]

thanks for your input...will check this out as well...my mechanic is pretty good...

 

[teddyd49]

How does one determine WHICH injector pump is installed in a 240D?? If there are two types of pumps, are there markings on the unit or pics somewhere to direct one to which pump he is working on? Thanks.

 

[teddyd49]

Finally got back to car yesterday with mechanic...got the A/C working again with a new compressor after 15 or more years without the A/C working in this car. Discovered that the radiator is missing its overflow tub and hose connection/nib into the side of radiator opening/cap holder.....more issues.....will probably have to purchase another radiator unit WITH this attachment as I am losing coolant each time pressure builds when car starts up out the open small hole below cap mount.

Took another look at injector pump leak with your previous input in mind. There is definitely a serious leak (perhaps as much as a 1/2 gallon of fuel spilling out with each full tank of diesel....an estimate of flow). There has formed a gooey crust all around the base of the injector pump.

This pump is NOT the one you sent a picture to me to exhibit the injector pump. Also, the leak is not happening in the TWO circled areas you cited. I was unable to ascertain WHICH pump this is but it must be the other of the two possible injector pumps you cited in your last missive. The leak is emanating from the bottom left hand area of the pump (the other side on the lower far left side of pump assembly). It is leaking where the fuel actually goes into the injector pump body. There is also an oil line going into this area. I have attached pics but they didn't come out too well owing to the poor light source and black **** that surrounds this part of the pump externally.

My mechanic asked if there is a "timing shaft" going into this area of the pump if he is to open the pump up in order to craft/install a new gasket for this area of the pump?

Is there somewhere that we can acquire an already calibrated replacement pump for this item if all else fails? Is there anybody today doing this kind of work on diesel injector pumps other than a Mercedes dealership? I would hate to think about what this might cost.

As I've stated before, we get one thing done and another thing needs fixin' but I do love this car and we're just doing things one step at a time. Thanks in advance for any ideas you might have as to how we can fix this leakage problem. Cheers!

 

[300Dman]

You are right I could not tell from the Pictures. Try again during daylight.

The Fuel goes in and out of the Pump Housing and to the Injectors.

That has nothing to do whith where the Fuel Injection Bolts up to the Block or the Timer inside the Engine. If those have a leak it would leak Engine Oil.

Any Bosch Certified Shop has the ability to take the Pump completely apart and rebuild it.
Or, they may just be able to fix the leak.

Alos for around $250-300 you can get a used Fuel Injection Pump on eBay.

The Fuel Line that goes from the Filter to the Fuel Injection Pump has what is called a metal fitting; a Banjo (that the Hose attaches to), Bajno Bolt and 2 Crush Washers that seal the Banjo.
The Stock Washers are Aluminum and generally can not be reused as much as the Copper Ones. If it is leaking there try getting 2 Copper Washers to replace the Aluminum ones and see if that fixes the leak.

What City and State are you located in. Perhaps one of the Forum Members with more experience would be willing to take a look and they could say exactly what is leaking.

In the picture below the Fuel goes into the Fuel Injection Pump in the Area of the Red Circle. See if you can give better directions to where the leake is.

The Blue Arrow points to the Fuel Supply/Lift Pump.

The Red Arrow points to the Hand Primer that is attached to the Fuel Supply/Lfit Pump.
In this case that is a new Style Hand Primer; the old ones have a shiny Aluminum Body and a hard Plastic Knob that is mostly White colored but sometimes Black.

 

[teddyd49]

The car is in Southern Florida...Palm Beach....so if anyone on this forum has knowledge of this problem and has time to take a look at the engine, would most appreciate it...thanks.

 

[teddyd49]

Better Pictures

I've attached better pictures of the problem with my injector pump...hope this helps in better identifying the problem....can you tell from these pics what type of fuel injector pump this is? There are evidently two types of pumps. The pic you originally sent me was NOT the same pump....close but different. Also, my original engine threw a rod and cracked the original engine about five years ago. This is a replacement engine and might be older than a 1982 diesel engine.

I've also attached a pic of the top of my radiator....the pressure plug and holding tank for overflow coolant (at start-up) is missing (for how long I don't know). Is there any way to FIX this problem without having to buy a brand new radiator with this attachment? The radiator itself is in good shape.

Once again, thanks for any and all input. Cheers.

 

[mrspaz]

If the place where the rag is located is where the fuel is leaking, then it may be coming from the hand primer pump. Unfortunately the primer pump is blocked from view in every picture.

If you still have the type of primer pump that is the "screw-in" plastic handle style, then they are notorious leak spots. You can replace the entire hand pump assembly with a new design from Bosch that is both easier to operate and less prone to leakage (like this).

As for the radiator; as far as I know the 240D / 616 didn't have an overflow / capture tank. There's normally just a length of rubber hose that attaches to that hose barb and runs down the side of the radiator to the bottom of the car where it empties to the ground. Obviously the hose barb on yours is snapped off, but unless the system pressure is rising high enough that the overflow valve on the cap is opening, nothing should come out of that hole.