Mercedes 240D 123.123 619
Finally, I got around to replacing the gasket between the injection pump and the motor block. What a massive amount of work to replace such a small gasket! It seems that cars just were not designed with servicing in mind.
I could not find the Hylomar Blue and, based on a discussion in this group in the past, I picked Aviation Permatex from a lot of others. It is supposed not to harden and that should make it more effective in the long term. What surprised me is the width of this gasket and the width of the metal-metal contact. In places it is only
3/16". I would think that a wider bearing surface would give much more resistance to leaks.Of course I had to remove the complete injector pump, after disconnecting the vacuum line (just pulling it off the pump), the two control rods, and the eight fuel connections:
1 Below the hand pump - the fuel inlet from the tank via the small transparent filter. 2 Right beside No. 1 - again below the hand pump - is an outlet that goes up to the top of the main fuel filter. 3 This is the fuel outlet from the main filter down to the front connection of the injection pump. 4 This one is the fuel return line that starts on the engine side of the injection pump, goes to the top of the main fuel filter and then attaches to the return line that goes back to the tank. 5 The other four are the metal fuel lines to the injectors.Lastly, I removed the three nuts and washers that held the front of the pump to a bracket at the front of the engine, and another three that fixed a small bracket to the rear of the pump and to the engine block. The pump then was removed, with the rear end down to keep the oil from running out the front. I placed it level on a bench top and noticed the oil coming out the front. That was the area where the gasket was to be located and, to prevent any more oil mess, I turned the pump with that end down and drained about two cups of oil. I sure didn't want it dribbling out after I had the gasket and cement in place.
The Permatex - Aviation comes in a 4 oz bottle with very few instructions. Basically: "Apply to thin film to each surface. Allow to air dry for a few minutes before assembling." This was all that applied to what I was doing. I went online and came up with a PDF (
What a ghastly, messy, stinking - especially in a hot garage - and primitive process this is. Why not a liquid-air separator valve attached to the tops of lines 3 and 4 with the air line heading into the air intake and the liquid heading into the return line to the tank? Now that would be civilization! :-) Anyone heard of such a gizmo?
Is it possible to buy the manual pump plunger itself, or the washer that presumably attaches to it?
I want now to stop all the drips from the engine and I noticed that there was a small leakage at the corner of the cylinder head gasket - the left front side. I tightened the nuts to the correct torque and I suspect that the cover may be a little distorted. The gasket is only a few years old. I am thinking of removing the cover and gasket to clean them up and then use the Permatex at that corner, or possibly the complete gasket. This sealant seems to have an alcohol base so I doubt it would bother the plastic of the gasket.
I won't be able to identify other leaks until I get the car to a radiator shop to have the engine box and the outside of the radiator very clean. Anyone know what this typically costs?