High Pressure Diesel Injector Pump Seal Replacement

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rsmarais

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No, there is nothing on the pump that is adjustable at all. Not on my 270 anyways. My guess is that they are trying to scare you into having them rebuilt it for you? Not sure why else they would say that.
 

Christopher C200

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Many thanks.
I did wonder as no one had mention it and I couldn't see any way to adjust/calibrate the pump.
I will order the kit and look forward to getting the car running again.
Christopher
 

Alex Crow

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As above, you can change the seals as many have - no need for any special testing or setting up.
 

Faheim786

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Hi there what a superb write up I would appreciate advice ,I have read your write up and I got the seal kit from Mercedes , what I would like to know is can I only replace the three head seals without opening and removing the circlip section as well as the whole centre portion


Thanks in advance
Mohamed
 

stevenN

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I've noticed a steady drip from the pump area on my car.
Not constant but still a worry.
Does anyone know of a picture link to o-ring replacement and pump removal on a
E220CDI W210?
I understand the pipes/clips can be easily so any tips appreciated
 

mersum1es

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I've noticed a steady drip from the pump area on my car.
Not constant but still a worry.
Does anyone know of a picture link to o-ring replacement and pump removal on a
E220CDI W210?
I understand the pipes/clips can be easily so any tips appreciated

It's very similar job than pics showing in this thread. You'll have plenty of space because of 4 cyl engine ;) Remove serpentine belt first, it helps a lot.

Start with o-rings of the low pressure hoses and test it (if you've not sure that leak is coming below the pump head) leak source is sometimes difficult to see...
 

raginbull

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CLK 270 cdi 2003
I've noticed a steady drip from the pump area on my car.
Not constant but still a worry.
Does anyone know of a picture link to o-ring replacement and pump removal on a
E220CDI W210?
I understand the pipes/clips can be easily so any tips appreciated

There was a very good picture explanation on this thread, I,m not sure if it is still here. I used it to replace the seals in my pump (270cdi). Its straight forward job just a little fiddly and you need to be methodical in your approach.
 

raginbull

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Thanks to everyone, especially rsmarais, for the superb write-up and information on the repairs to the pump.
I have spoken to my local Bosch agents to order the kit and they have warned me that the pump will need calibrating after the service.
This has not been mentioned in the threads and would be grateful to learn whether this is really necessary as I am sure that someone would have brought the matter up.
Many thanks,
Christopher
W203 Estate C220cdi

When they say "calibration" I guess they mean testing, The kit I got from MB only had the seals for the 3 heads so I never dismantled the inner bit. To test (calibrate) it I put it back on the car, primed it and hey presto no leaks and no starting problems.
 

Alex Crow

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No calibrating of pump required, if changing any of the seals.
Cleanliness however, certainly is required.
 

Neil1664

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Hi All, could anyone please confirm the part numbers for the o rings on the two clear pipes that connect to the left hand side of the pump? MB have sent me a diagram but it's not clear.. Mine is leaking but think its just from there.
 

Alex Crow

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stevenN

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Hi Alex are these pretty universal?
Also is there a knack to getting the pipes off without breaking the clips?

Cheers

Steve
 

Alex Crow

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Yes, and yes.

The pipes all have white dismounting clips fitted - just push the horseshoe clip in to open the black tangs.
 

W163

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How to unlock the head's bolts?

My pump was leaking diesel fuel and I decided to replace all seals. The seal kit MB I bought doesn't contain the two seal rings of the inner main shaft, so I'm not sure to solve my problem. Also, I find very difficult to loosen the bolts of the head. I used bits torx with a T-handle, an impact driver, a pneumatic impact wrench, but the bolt are still there. I tried to warm up the bolts, but nothing has changed. Have you any tips to give me?
 

mersum1es

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W212/-09/350CDI, W219/-07/320CDI, EX:W220/-01/320CDI, EX:W211/-04/320CDI, EX:W210/-01/270CDI
My pump was leaking diesel fuel and I decided to replace all seals. The seal kit MB I bought doesn't contain the two seal rings of the inner main shaft, so I'm not sure to solve my problem. Also, I find very difficult to loosen the bolts of the head. I used bits torx with a T-handle, an impact driver, a pneumatic impact wrench, but the bolt are still there. I tried to warm up the bolts, but nothing has changed. Have you any tips to give me?

Ask bosch service, they may have other seals too...

I used this kind of impact driver: http://i583.photobucket.com/albums/ss273/Kimmo-89/Muut/S1uudetosat013.jpg required two hits/bolt by ~1kg hammer... problem is if you have already rounded head of the bolt.
 

raginbull

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CLK 270 cdi 2003
My pump was leaking diesel fuel and I decided to replace all seals. The seal kit MB I bought doesn't contain the two seal rings of the inner main shaft, so I'm not sure to solve my problem. Also, I find very difficult to loosen the bolts of the head. I used bits torx with a T-handle, an impact driver, a pneumatic impact wrench, but the bolt are still there. I tried to warm up the bolts, but nothing has changed. Have you any tips to give me?

Hold the pump securely in an engineers vice and try turning in a clockwise direction slightly before undoing, this sometimes works. Also you could leave it to soak in a container of penetrating oil overnight after a little heat.
 
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kleistc220

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thanks for this amazing post. do you know the size or part number for the head bolts?
 

mersum1es

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stevenN

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Yes, and yes.

The pipes all have white dismounting clips fitted - just push the horseshoe clip in to open the black tangs.

Hi Alex

looking at the photo of the pump in this thread
the clips that hold the pipes to the pump look different to the ones where the pipes attach to the fuel filter.

I have yet to clean the crud off and take a look.
But it has got to be done

Are they the same as regards to method of removal?

cheers

Steve
 

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