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Old 12-18-2013, 01:10 AM   #1
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Default OM612 injector/high pressure pump replacement

My injector pump started leaking on the serpentine belt at first start-up in 30 degree weather. This is a common issue with older vans, the seals getting old less pliable due to temperature.

Dec/15/2013
I purchased my pump used on ebay for $165 with a one year guarantee. New pumps are $1500-1800, rebuilt $700-1000, and the re-seal kit (usually unavailable) is $70.

This job requires Torx bits from T20 to T60, E-Torx sockets or maybe you can get away with 12-point sockets in the right size. You will need a reversing clamp or block of wood to hold radiator away from engine. You will want a can or two of carburetor cleaner available, and rags for cleaning. Below method does not require draining the radiator or fuel lines.

Removal
1. remove the front grill
2. take off headlights
3. remove turbo heat shield
4. remove crossbar (remove hood latch wire through slots in mechanism after crossbar is off)
5. push top of radiator assembly away from engine (I used a reversing clamp), taking care to
not damage anything or loosen hose attachments.
6. remove fan (T60? bit, some sort of bar to prevent engine turning, I used a large pin driver)
7. remove steel fuel line using two wrenches, do not bend line.
8. remove clamp holding feed and return plastic fuel lines (E socket), pull/twist lines out from
pump, protect lines from dirt, I use examination gloves. Unhook electrical connection.
9. remove three bolts (E socket) and pull/twist injector pump from engine. You may have to
pry one side then the other until it starts moving. Be careful of the interface parts that the
pump inserts into on the engine.

Halftime
Clean the area behind and below the pump, you may never have another chance!

Prep the replacement pump. My new used one was not cleaned when I got it, and the electrical connector was damaged either by the vendor or in shipping, I replaced it with the one from my old pump. I placed a new o-ring on the shaft that inserts into the engine, metric 326 I think; I have a metric o-ring multi-kit from harbor freight that had an exact match. Pictures show some possible oil leakage from the engine due to the o-ring on my old pump. Replacement pump was cleaned with carb cleaner and a brush and lint-free cloth. Be VERY careful to protect the fuel line connections and assure that they are clean as well, science lab clean.

Installation
Reverse order of installation
1. match drive wheel angle to slot in engine using old pump as example
2. smear some fresh oil on the o-ring and insert (push/wiggle) pump into engine
3. inspect to make sure it is fully inserted and o-ring is still where it belongs
4. replace three bolts to hold it on; bottom one is difficult, I used a mirror to check position.
The plastic fuel lines and the serpentine belt are slightly in the way and I used a screwdriver
to lever them down a bit while I started the bolt.
5. attach steel fuel line, electrical connection, and feed and return lines. Take care to insert
plastic lines correctly and not at an angle so the square side o-rings stay in place. The
plastic line heads have indents and stops on them that the metal hold down bracket mates
with. I re-used the existing square side o-rings and white rubber washers with no problems.
6. remove blocking/clamp behind radiator assembly, inspect hoses and connections for
loosening.
7. re install hood latch wire and replace crossmember
8. install headlights
9. install grill

Crank to start; this lets air in to the system, and I had to crank for about 20-30 seconds to purge/prime and start the engine. Bubbles in the fuel line went away during a 5 mile drive.

*the manual says to disconnect the battery, I didn't.
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File Type: jpg Dsci0219.jpg (133.9 KB, 473 views)
File Type: jpg Dsci0218.jpg (146.5 KB, 454 views)
File Type: jpg Dsci0217.jpg (125.9 KB, 457 views)
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Old 12-19-2013, 06:41 PM   #2
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Thumbs up Re: OM612 injector/high pressure pump replacement

I just want to say thats a great post!! It looks like I have the same problem with only 70,000 miles. 2006
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Old 12-19-2013, 07:10 PM   #3
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Default Re: OM612 injector/high pressure pump replacement

It is a good Write-up.

Quote:
Originally Posted by mcsherryrick View Post
... It looks like I have the same problem with only 70,000 miles. 2006
It may not be the *same* problem. The NAS 2001 - 2003 T1N's have a different high pressure fuel pump from the NAS 2004 - 2006 T1N's. Your style pump has a history of the fasteners loosening and causing a leak.

Before buying any parts try this:

Do an advanced search using "abittenbinder" and maybe "fuel pump loose" key words. Select the T1N section and click show "posts" in the lower left. That should get you the details.

Basically...

Remove the pump.
Check for loose fasteners on the back.
If they are loose, remove one at a time, apply Loctite, and re-install.
Your leak will likely go away.

vic
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Old 12-19-2013, 07:19 PM   #4
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Default Re: OM612 injector/high pressure pump replacement

Yes, great write-up with pics! I know that it will help a lot of folks!
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Old 12-22-2013, 04:38 PM   #5
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Default Re: OM612 injector/high pressure pump replacement

I don't know if I mentioned that it was a pretty easy job. Anyone with the right tools can do it, it does not require any scanning device or specialty tools, nearly as simple as replacing the fuel filter. You don't have to remove the vacuum pump, low pressure pump, or drain any fluids. The trickiest part was removing and replacing the lower bolt, because you can't actually see it while you're doing it (use a mirror). The main thing is to to keep everything CLEAN CLEAN CLEAN when any of the connections are open or the pump removed. If you have the ability, steam cleam the entire area before disconnecting or removing anything.
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Old 12-22-2013, 05:40 PM   #6
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Default Re: OM612 injector/high pressure pump replacement

I need to change pressure relief valve, it drive me crazy (noise) I might consider to remove hp pump one day to change it ( don't know, if this is good thing to do it, some folks do this with pump in place, but looks very tight to me) or I just swing the radiator away, good job with your write-up - thanks!
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Old 12-22-2013, 05:56 PM   #7
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Default Re: OM612 injector/high pressure pump replacement

Vic/AP/SOB,
OK, I'll bite.......
What exactly is a NAS 2002-2003 Sprinter and how is it different than a NAS 2004-2006 Sprinter?
I KNOW the differences between a 2002-2003 T1N Sprinter with the OM-612 5 cylinder 2.7 liter engine with the vacuum turbo boost level controller (vacuum powered turbo actuator) and a 2004-2006 T1N Sprinter with the OM-647 5 cylinder 2.7 liter elephant trunk engine with the electronic turbocharger actuator.
So, what the heck does "NAS" stand for?
All Sprinters shipped to the USA/Canada (the North American Free Trade Agreement (NAFTA) sales region) I also understand, but someone seems to have dropped another acronym (NAS) into the mix to further confuse our new members and readers.
NAS is the common USA acronym for National Aerospace Standard and has nothing what so ever to do with our Sprinters (of any vintage).
Inquiring minds would like to know where this came from, from whom, and their rationale for further confusing the Sprinter acronyms issue.
Roger
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Last edited by sailquik; 12-22-2013 at 07:15 PM.
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Old 12-22-2013, 06:39 PM   #8
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Default Re: OM612 injector/high pressure pump replacement

Quote:
Originally Posted by sailquik View Post
So, what the heck does "NAS" stand for?
NAS stands for North American Specification. It is used widely in the UK (and probably European) car industry when referring to any motor vehicle destined for the USA.

As an aside I have worked for a major UK motor manufacturer for nearly 25 years (one that Dennis is well acquainted with) and had not heard the term NAFTA until buying a Sprinter and joining this forum.

Keith.
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Old 12-22-2013, 06:39 PM   #9
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Default Re: OM612 injector/high pressure pump replacement

Quote:
Originally Posted by sailquik View Post
Vic/AP/SOB,
OK, I'll bite.......
...Roger
Roger,
Sorry for the confusion. NAS is North American Specification. A while ago someone here pointed out that NAFTA doesn't really apply. The Sprinters shipped here are subject to having some of the identical basic equipment (no 4x4 for example) so NAS is probably more descriptive.

The Sprinter shipped over here disassembled is really to avoid the "Chicken Tax". It has nothing to do with the North American Free Trade Agreement because they come from Europe.

So maybe CTS Chicken Tax Sprinter doesn't have the same ring to it?

Anyway. You're correct that we are likely stuck with NAFTA as it has been used for so long.

Just think of it as another acronym to confuse the new people.

vic

P.S. - I use 2001 - 2003 because there was a handful of 2001 Sprinters shipped to North America.
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DAD NAS (N. Amer. Spec) 2004 140 2500 >330,000+ mi. Arctic Whitewash Brush-tone Grey
2006 Freightliner 140 2500HC >183,000+ mi. Arctic Whitewash (Spotted Snow Leopard accents)
"My opinion and worth everything you'll never pay for it." assumed.
Anyone can hold the helm when the sea is calm. Publilius Syrus
"There are only 10 types of people in the world: Those who understand binary, and those who don't." HaWiiLuVeR
16 ounces of unnecessary prevention can be worth a pound of manure.

Last edited by Aqua Puttana; 12-26-2013 at 03:21 PM.
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Old 12-25-2013, 08:03 PM   #10
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Default Re: OM612 injector/high pressure pump replacement

Quote:
Originally Posted by Aqua Puttana View Post
Roger,


P.S. - I use 2001 - 2003 because there was a handful of 2001 Sprinters shipped to North America.
2,000: http://sprinter-source.com/forum/showthread.php?t=7736
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