606 leaking diesel again - PeachParts Mercedes-Benz Forum

sokoloff · #1 05-03-2007, 06:41 PM

Was under my car today removing the noise encapsulation panels to do my sway bar links and bushings when I noticed some wetness. Upon removing the panels, I had a little puddle in one of them and a very wet oil pan. See photos attached. I replaced all the fuel lines a year and a half ago as well as the fuel shut off unit. So what should my plan of attack be now? Shall I replace all of the O rings with viton? Since the hoses look pretty good yet and are dry, I'd like to leave them alone if that makes sense. Is there a comprehensive list of the O rings and gaskets I need to do this? Terry, Marty or Jim? Don't know if I must remove the intake manifold, but I will since for me it is an easy job and is so much easier to reach everything. I'll probably also take the plunge and see if all of my glow plugs will still come out ion one piece.

aklim · #2 05-03-2007, 06:46 PM

Removing the manifold makes it easier to work and you can take out the GPs to make sure they aren't seized. Can't hurt. $10 for the gasket.

I replaced all my lines with regular MB stuff and it was fine then and still is now.

aklim · #3 05-03-2007, 06:48 PM

Could the Shutoff Valve be leaking again?

TMAllison · #4 05-03-2007, 07:28 PM

I've posted the o-ring sizes if you want to change them rather than the lines too. Let me know if you can't find it and I'll send it to you.

I think JADAVIS may have those o-rings stocked now?

Looks pretty clean and dry except for the EGR and the drop at the shutoff valve.

Only thing I would question is if there is staining around the hold down washers for the delivery valves? Check DV #6 and see if it is the culprit for the wetness at the rear of the IP or possibly one of the fuel lines on top of the lift pump.

If you've got enough of a leak to make a puddle on the pan you should be to find it.

sokoloff · #5 05-03-2007, 08:19 PM

Thanks guys. I guess I may as well yank the manifold since the car is out of commission anyway and see what's up.

Aklim - I do have a manifold gasket on hand and, yes, the fuel shut off could be leaking again. I happen to have two viton O rings on hand for that that I just got a week ago. Never expected to need them so soon Terry.

I'll take it apart, see what's leaking and let Jim know what I need. If I'm lucky, it may only be the shut off valve O rings.

nhdoc · #6 05-03-2007, 08:39 PM

Hi Len,

It does look to me that it is your shutoff valve that is causing most of the problems...start there with that ring and see how it looks afterwards. My last one only lasted about 18 months before it started leaking but I blamed it on the change to ULSD which caused my DV's to leak too last fall. You don't need to pull the IM to change the shutoff o-ring though, just go in from the side after moving the washer bottle.

Personally my advice with the GPs would be to leave them alone if they are working...pulling them as PM is looking for trouble. I plan on simply replacing mine on a need-be basis from now on since I know the risk of breaking one off is not small and the fix for that can be very costly. Just my $0.02.

connerm · #7 05-03-2007, 09:22 PM

When I replaced the delivery valve seals and washers, I noticed that the fuel heater was lose! I tightened it up to about 10nm and no more leaking from that spot. I would have been highy irate to have gotten it all buttoned back up after doing the valve seals only to notice fuel leaking. Check all nuts and bolts while the intake is off. Don't go crazy with torque and leave the glow plugs alone. And leave the glow plugs alone. Also, fuel supply line was in pretty bad shape under the hose clamps. Also, while you have the intake off, replace the overflow hoses. Search this forum for the procedure.

WINGAS · #8 05-04-2007, 01:13 PM

My return lines leaked. If you find and fuel on the back of the cylinder head, pop the cover. I had two puddles!

Jadavis · #9 05-04-2007, 01:50 PM

http://www.fryerpower.com/store/page11.html

Is the shut off valve o-ring the 2.5mm x 18mm that I still need to order?
Is there anything else I need to stock? I hate ordering just one or two bags of o-rings (but I will

) The shipping is the same on that as it is on 20-30 bags. If there is anything else I don't have that you know the sizes of let me know.

-Jim

TMAllison · #10 05-04-2007, 02:01 PM

For Len's 606.962, the count and sizes should be:

1 shutoff valve 2.5mm x 12mm ID
9 fuel line 2.5mm x 8mm ID (1 located at fuel filter housing)
3 fuel line @ filter housing 2.5mm x 10mm ID
1 pre-filter 3mm x 18mm ID

He already has the shut off o-ring.

Jadavis · #11 05-04-2007, 02:04 PM

Sweet! That is something I can sink my teeth into!

I'll do a big order today and get them listed on the site.

Thanks,

Jim

sokoloff · #12 05-04-2007, 02:27 PM

Okay, here's an update, with photos for those of you that are visual learners like me.

Opinions welcome here. I removed the manifold today and based on what I see so far, I'm thinking of just replacing the two O rings on the fuel shut off unit with the viton ones I have on hand. But I'm saying that and looking at this leak and wondering how what appears to be a small leak at the fuel shut off can cause such a mess. I'm certainly not opposed to doing more while I have everything apart though - please speak up.

On the EGR unit, I have a replacement O ring for inside the unit, but it looks like a lot of that leak it from above that joint. Maybe the square gasket near the top of the unit is the culprit.

Thanks for your ideas.

aklim · #13 05-04-2007, 02:29 PM

Can you clean off the thing with brake cleaner and then run the engine and watch where it leaks at? With some sort of dye in the fuel if possible. I ran the engine with the manifold off

F18 · #14 05-04-2007, 02:49 PM

Len....I hate to say this but you said to speak up!
The locking plates and screws for the IP valves in your picture still show the original factory yellow paint streak on them. If thoughs are the original IP delivery valve "O" Rings in there you might as well change them out now while you have the manifold off. If not they will probably start leaking over the summer and you will have to pull it again. I am sure you'll want to spend your Saturdays at the beach than doing that job all over again........
Cheers

TMAllison · #15 05-04-2007, 03:08 PM

You only need one shut off o-ring, I gave you an extra one for "next time" Len.

I'd spray everything down with cleaner and run it to confirm where it is comming from. You can run it w/o the IM installed; it will be a lil stinky from exhaust and may throw a code but wont hurt anything and you can clear the code afterwards. Make certain nothing is in or around the intake valve openings; you dont want to suck anything in by accident.

Is quite possible the fan is blowing the drip off the shutoff valve back onto the rear of the IP but that seems like a long ways for it to travel horizontally.

To do the shut off oring you dont even have to disconnect any fuel lines or the electrical connection so definately easiest to start there. Just need to pull it back an 1" and slip on hte new oring.