W203 - C220 CDI - Fuel Pump & Pipe Leaks Help

[Edlosoldier]

Thanks mate

 

[VinoVito'd]

A final note to finish off this thread.

It appears that the fuel pump on you van's are pretty much the same as that on my 2002 2.2 Vito. They also happen to be pretty similar to my 2004 Hyundai Sant Fe 2.0 CDRi 16. egine.

I had a diesel leak on my Santa fe 3 weeks ago. like everyone else, i panikced, but got my tool out, went on ebay and found a new O-ring /Gasket set for the whole high pressure pump for £26 delivered.

I did the job myself with minimum fuss. Job was worth around £200 according to my friend who is a mechanic.

Very pleased with myself so far. I would actually say it was an easy job, though the Santa Fe is very easy to work on.

My Vito on the other hand....pfffft. I'm not looking forward to taking the car apart to get to the pump. I have my Fuel shut off valve disconnected by the previous owner. No Idea why, but it's in Limp Mode.


Anyway, I thought I'd just add this for anyone suffering a fuel leak on these Bosch High Pressure Pumps. Can be fully repaired (seals and O-rings only, for less than £30 and a couple of hours of your time) I did have to re torque them bolts to 25nm.

 

[Aavish]

Big problems this morning, went out to the car bright and early, started the car and it fired up no problem however after five seconds it cut out. Tried a few more times and could tell it just wasn’t going to fire and to save the battery stopped.

This is the first it has ever failed to start (apart from seat controller drain of course)

Anyway before deciding what to do pulled out the mux and DAS and no fault codes showing however after checking actual values no pressure at the injection rail.

As I’m at the G/Friends I was in two minds what to do, pull it apart or phone the AA. Decided to have a look and see if there is anything obvious. Easy answer to that, diesel down the front of the engine, right time for the AA.

Didn't take long for them to turn up and after explaining what I’d found he set about cleaning the area around the pump and pipes and found the pipe attachment at the outgoing side of the fuel pump was leaking. No sign of damage to the o-ring or the connector but it was still passing. Anyway in the way of a temporary fix he wrapped the plastic connector in a clear PTFE type tape to seal it and after putting back together it fired up and a few cranks, obviously air taking it's time to release.

I thought this was the end of it, afraid not, a steady drip had appeared under the car and looking around the pipe entering the high pressure pump it seemed to be coming from this area. A torch highlighted exactly where it was coming from, the left hand side of the high pressure pump to the rear of where the plastic pipe connects to it.

Bottom line not going anywhere, it's getting recovered tomorrow and I’m in the process of going through part numbers etc on the EPC.

My question to those that know about these high pressure pumps, there is a repair kit available for the area where the leak is coming from. What is included in these kits?

I'm planning to replace the fuel pipes as they seem very brittle.

First Leak: - At item 137 at the upper Fuel Pump
Second Leak: - At item 164 at the Hig Pressure Pump

So hopefully the repair kit and the new pipes will solve the problem or I’m looking at a new high pressure pump.

Item 25 is the repair kit:-

Does anyone know the part number for item 62 and 68 ?