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Old 05-27-2010, 04:59 AM   #1
abittenbinder
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Default Dr.A TECH ALERT-647 High Pumps

As many 612 owners have discovered, '02-'03 612 Sprinter high pressure pumps are prone to degradation of internal seal elements of which there are many. The result is external fuel leakage along the front of engine. I have offered an economical rebuilding service for these 612 high pumps for quite some time.

647 Sprinters ('04-'06) have a very different high pump design. The cast steel portion is now a mono-bloc design which eliminates many of the seals that degraded in the earlier 612 pump design.

The 647 pump has a separate aluminum base console (flange) which houses all the passage ways and control elements for fuel metering into the pump and for return flow out of the pump.

These 647 pumps are increasingly developing external fuel leakage (similar symptoms to the 612 pump leakage). Unlike the early pump's high pressure leakage this is feed pressure leakage but just as troublesome.

The cause appears to be gradual loosening of the 6 internal socket head (Allen) bolts securing the aluminum base console to the steel pump body. Dissimilar material expansion, heating and cooling cycles and vibration are the challenge here.These 6 bolts are accessible only from the back side of the (removed from engine) pump.

When these bolts loosen, an internal array of seal rings develop leakage and fretting typically occurs between the pump and console castings.

An emergency fix involves re-torque of the bolts but the more reliable fix is professional disassembly of the pump and replacement of all internal seals after refacing the affected surfaces and reassembly using bolts with locking agent.

I offer this service to 647 owners at a significant savings from factory rebuilt. Contact me directly for details. Doktor A 864-623-9110

Last edited by hkpierce; 07-24-2017 at 07:37 PM.
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Old 05-27-2010, 05:09 AM   #2
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Default Re: Dr.A TECH ALERT-647 High Pumps

Andy any chance of some photos please
Locking agents!I assume you mean thread lock as like ;example Victor USA V-264 or Loctite 222-290 varying in grade for locking compounds on threads.
Richard
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Last edited by Altered Sprinter; 05-27-2010 at 05:21 AM.
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Old 05-27-2010, 12:21 PM   #3
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Default Re: Dr.A TECH ALERT-647 High Pumps

Quote:
Originally Posted by abittenbinder View Post

...

An emergency fix involves re-torque of the bolts but the more reliable fix is professional dis-assembly of the pump and replacement of all internal seals after refacing the affected surfaces and reassembly using bolts with locking agent.

...
Andy,
Should we remove the pump for tightening before the failure? Will an early one at a time bolt removal, locking agent application and re-torque of the bolts avoid the future problem? Thanks very much for the heads up. vic
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Old 05-27-2010, 04:01 PM   #4
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Default Re: Dr.A TECH ALERT-647 High Pumps

I to am very interested in this. WVO use I amagine would further aggrevate this situation. I.E. heated fuel
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Old 05-27-2010, 04:38 PM   #5
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Default Re: Dr.A TECH ALERT-647 High Pumps

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Old 05-27-2010, 04:49 PM   #6
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Default Re: Dr.A TECH ALERT-647 High Pumps

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Old 05-27-2010, 08:16 PM   #7
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Default Re: Dr.A TECH ALERT-647 High Pumps

Is there a threshold number of miles associated with this issue? thanks, paul
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Old 05-28-2010, 12:48 AM   #8
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Default Re: Dr.A TECH ALERT-647 High Pumps

I have been talking to The Doctor about this the last couple of days.BECAUSE it just happened to me.I was really freaking out at the prospect of having to spend over 2grand(installed) on a new(reman) pump!!!Days before a 1,000 mile run.My van only has 66k and once it started leaking it got worse really fast.It leaked from just the lift pump pressure with the key on.It leaks from behind the pump and I had to remove the heat sheild over the turbo to be able to see where.I'm lucky the I was able to find someone to even work on it.I'll post the shop info when we get home next week.And it was refreshing to find someone that knows a lot but doesn't know it all(if you get my drift) Three of the screws were loose,1 about to fall out.So far so good.Locktite and retighting has stopped the leakI'll see how it does on the trip home and let you all know.It seems to be working fine.I agree with Andy about the seal kit but we had a deadline and couldn't wait.These van's would be a LOT more expensive to operate
with out people like Andy and John(Sprinter store).A BIG thanks from me to youall!

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Old 11-15-2010, 12:30 PM   #9
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Default Re: Dr.A TECH ALERT-647 High Pumps

Quote:
Originally Posted by Aqua Puttana View Post
Andy,
Should we remove the pump for tightening before the failure? Will an early one at a time bolt removal, locking agent application and re-torque of the bolts avoid the future problem? Thanks very much for the heads up. vic
Hey Vic
Great question!

My pump started leaking a couple days ago. Leaked quite a bit during glow plug warm up before engine start. When I removed my pump 2 of the 5 bolts holding the pump together fell out on to the ground.

REALLY!!

I thought motobueno was embellishing his story just a bit. Yea, bolt about to fall out.

How did my pump stay sealed with 2 bolts totally loose and 2 others finger loose?

These bolts are only accessible from the rear of the pump after removal. After locking agent application and re-torque of the bolts all is good.

T27 torx bit

I wish 2 weeks ago when I had the fan off I checked the bolts on this pump!

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Last edited by dbeyer; 11-15-2010 at 12:33 PM. Reason: I had thoughts
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Old 11-15-2010, 01:07 PM   #10
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Default Re: Dr.A TECH ALERT-647 High Pumps

Some owners have sent me their 647 pumps for a more thorough inspection and repair. I frequently observe missing bolts that they may have dropped.

Some of these pumps have exhibited erosion wear of internal seals and fretting of the machined interface which I then rebuild.

On the other hand, I have seen 647 pumps with very high mileage with fully torqued hardware. Quite unpredictable. Doktor A
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