First things first , ALWAYS because failure to do so means you'll wind up chasing your tail .
Go get some of that special DIESEL rated fuel hose and replace ALL of the hoses , I find a pair of duck bill pliers and a dykes do the job well .
Then drive it a bit to bleed out the air and see if it runs better .
Remember : the fuel injectors MUST BE POP TESTED AND RECTIFIED BEFORE ADJUSTING ANYTHING ELSE ! .
The overflow pressure valve is on the inside of the injection pump and has a hard plastic translucent pipe leading from it's banjo bolt , up to the fuel filter plate .
Tuck a CLEAN light colred rag underneath it , pinch off the rubber fuel hose at the clear plastic intake screen then use a 17 MM open end wrench to loosen it , there's w black plastic wire connection you'll have to twist and pop off first else you'll prolly break it .
Once you have the valve/banjo bolt in your hand , wipe the threaded nose of it clean and try to blow though it ~ if you can , the valve is dirty or kaput , hold the bolt in a 17MM box end wrench and use a 14Mm box end wrench to loosen the top , lay it over a clean light colored rag and take it apart ~ not much in there , a spring , ball bearing and copper sealing washer .
Use Q-Tips and gasoline , alcohol whatever to swab the inside clean and rinse it well , take the time to clean ALL the parts .
If the Q-Tip even gets fine silt on it , you've found a serious problem .
Flip the tiny , delicate coil spring over 180° so the ball bearing goes in the narrower end as the slightly wide end is caused by wear over the millions of cycles .
Re assemble and tighten , don't forget the copper sealing washer , don't gorilla tighten it , just a firm squeeze , this is when the box end wrenches come into play .
When you go to re install it , swab out the banjo fitting n the end of the plastic pipe , finding any dirt / silt in there means you need serious fuel system cleaning and replace the secondary , spin on filer straightaway .
The banjo fitting has two aluminum crush washers , one on each side , the inner one typically falls down and vanishes , why you remembered (I hope) to tuck a clean , light colored rag underneath before beginning .
Support the banjo fitting as you snug up the bolt so it doesn't twist .
Remember to clean the engine of the spilled Diesel fuel when you're finished so it doesn't dribble down and ruin the motor mounts , ball joint dust boots and so on .
This simple thing adds quite a bit of power and amazing smoothness to the engine of any Mercedes Diesel .
Keep us posted , as always , work carefully and diligently , following the proper order and never skipping steps .
-Nate
Carl wrote :
Sometimes it's small details.... Where is the "fuel galley return hose outlet check valve"? I'm seeing bad leaking on the injector return hoses. The injectors aren't supplying the quantity of fuel, it is coming from the fuel filter. Is there supposed to be a check valve to avoid the flow from the filter banjo bolt to injector overflow hose?
Thanks for the info.
Carl
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Posted by: vwnate1@yahoo.com
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