601 602 603 Diesel Injection Pump Delivery Valve Seal Replacement Kit

Leaking fuel injector pumps have become a very common problem in the 60x. engines produced from the mid 1980's to the mid 1990's. The early 60x. group includes the four cylinder (601) engine that came in the 1984-1986 190D 2.2, the five cylinder (602) engine that came in the 190D 2.5 and 300D 2.5 from 1986 to 1993, and the 6 cylinder (603) engine installed in the 124, 126, and 140 chassis 300D / TD (1987 only), 300SDL and 350SDL from 1986 to 1993. (Later models also use the same o-rings, but my instructions may not apply.)

These were Mercedes new class of diesel engines with aluminum cylinder heads. All turbo models can be easily recognized by the flat intake manifold that goes from the turbo side of the engine over the middle center of the engine valve cover. The newer style injection pumps on these engines also have delivery valves on the top of the pump that are sealed with a rubber o-ring. Yup, guess what happens with 15 to 20 year old rubber o-rings? If you have no record of these o-rings being replaced I recommend you do it NOW!

I highly suggest you do it before they start leaking. If you are on a long trip you can really pump a lot of diesel out on the road. I include complete instructions on how to do this job yourself. On most engines it can be done without removing the intake manifold or the injector lines. If you are planning to change out your injectors or glow plugs (especially glow plugs) plan to do these o-rings at the same time. When the intake manifold is removed it makes access a lot easier. I cannot guarantee that you can do this job on all 60x. engines without removing the intake manifold. No instructions are included in this kit for removing the intake manifold. The job is time consuming but straight forward. I do recommend you replace the intake manifold gasket if you are planning to remove the intake manifold. Instructions for removing come in my manual on 60x Glow Plug Removal and Repair. CLICK HERE to order.

This complete kit includes the following:

• High quality specialized multi-point spline socket
• 6 OEM Mercedes rubber delivery valve o-rings
• 6 delivery valve housing copper washers
• Special pick tool to remove the copper washers
• One cleaning brush
• Thread locking compound
• Step by step illustrated instructions written by Kent Bergsma