Fuel injection pump repair

[Bambolera]

I was trouble shooting the fuel system on my Volvo MD3B today. Looks like the number two cylinder of the injector pump isn't pumping fuel (the first and third cylinder appear to be working fine). So... I disconnected the fuel lines and removed the pump. Then, I took a look at the schematics for the pump and started thinking that this project might be beyond my skill set.

Has anyone ever tried to repair a diesel fuel injection pump?

[DotDun]

Originally Posted by Bambolera

I was trouble shooting the fuel system on my Volvo MD3B today. Looks like the number two cylinder of the injector pump isn't pumping fuel (the first and third cylinder appear to be working fine). So... I disconnected the fuel lines and removed the pump. Then, I took a look at the schematics for the pump and started thinking that this project might be beyond my skill set.

Has anyone ever tried to repair a diesel fuel injection pump?

IMO, best left to the professionals. It's important that each cylinder receives the exact/same amount of fuel, hence calibration is normally done with a very expensive machine.

[Tellie]

Originally Posted by DotDun

IMO, best left to the professionals. It's important that each cylinder receives the exact/same amount of fuel, hence calibration is normally done with a very expensive machine.

I agree, most of the diesel is easy to fix with some patience. But the pump is best left to the pros with the right equipment.

[bobconnie]

As said, better left to a Pro!! and I hope ya marked where it was before ya removed it !!! saves a bunch of time and expense of paying a Pro to come to the boat and set up your timeing LOL

[hpeer]

Yes, I now THAT from experience!

[Bambolera]

Thanks guys. I didn't want to puss-out. What a relief!

[Bambolera]

Originally Posted by bobconnie

: I hope ya marked where it was before ya removed it !!!

What needs to be marked? The pump has four bolts and lifts straight out of the block. It can only go back the same way it came out. Since the motor is not running, nothing should change until the pump is returned.

The injector pump appears to have a slide mechanism on its side (are there other moving parts?). If the shop were to change the location of this lever, while making repairs and adjustments to the pump, they should return it to the original position, right? Do I need to mark the original location of the slide, just in case they forget?

Maybe there is more to this than I realize.

http://www.google.com/imgres?q=Volvo...9,r:2,s:0,i:96

[DotDun]

Originally Posted by Bambolera

What needs to be marked? The pump has four bolts and lifts straight out of the block. It can only go back the same way it came out. Since the motor is not running, nothing should change until the pump is returned.

The injector pump appears to have a slide mechanism on its side (are there other moving parts?). If the shop were to change the location of this lever, while making repairs and adjustments to the pump, they should return it to the original position, right? Do I need to mark the original location of the slide, just in case they forget?

Maybe there is more to this than I realize.

Google Image Result for http://www.volvopentashop.com/Catalogs/PentaParts/7742090/2426.png

I'm not familar with how Volvo times their pumps, with Yanmar, they use shims between the pump and engine block, hence the warning to use the same shims when reinstalling the pump. If you ruin the shims or install a different pump, it must be timed at installation (usually requiring a professional).

The lever you are referring to is the fuel control rack that mates with the governor. It's imperative that this goes back together correctly, if not, the governor won't have control of the engine and it may rev out of control upon startup if this is the only engine stop mechanism (no cutoff solenoid). Yanmar has a sight hole with a plate over it so one can verify the fuel control rack and governor arm has mated properly, again, I have no experience with Volvo but I would be surprised if there isn't some way to verify.

If you haven't thought about it, it may be worth having the same shop inspect and clean your injectors.

[Bilgediver]

Originally Posted by Bambolera

I was trouble shooting the fuel system on my Volvo MD3B today. Looks like the number two cylinder of the injector pump isn't pumping fuel (the first and third cylinder appear to be working fine). So... I disconnected the fuel lines and removed the pump. Then, I took a look at the schematics for the pump and started thinking that this project might be beyond my skill set.

Has anyone ever tried to repair a diesel fuel injection pump?

Generally the advice is do not touch fuel pumps as having tweeked them they may need recalibration. However there is one exception to this in my book and it does not require the pump to be removed from the engine.

There can be delivery valve faults so check if this is the case with No2. With the throttle at zero setting pump hard on the lift pump with the fuel pipes disconnected. If fuel comes from the fuel pump outlet then go no further as it needs a diesel injection specialist. If no fuel comes out while pumping the lift valve then loosen off the delivery valve very carefully so that trapped air in the pump can escape up the threads. Once air is out tighten the delivery valve and fuel pipe connections. I have had to do this a few times and it is a characteristic of some delivery valves.

If this does not work then you should be able to find a diesel injection service company in your yellow pages. The components are Bosch and available.

If you do remove the pump then make sure you do not lose any of the gasket shims and that you replace the pump using the same shims as removed . Failing to do this will affect the timing of injection.

[Bilgediver]

Originally Posted by Bambolera

What needs to be marked? The pump has four bolts and lifts straight out of the block. It can only go back the same way it came out. Since the motor is not running, nothing should change until the pump is returned.

The injector pump appears to have a slide mechanism on its side (are there other moving parts?). If the shop were to change the location of this lever, while making repairs and adjustments to the pump, they should return it to the original position, right? Do I need to mark the original location of the slide, just in case they forget?

Maybe there is more to this than I realize.

Care has to be taken when removing not to lose any gaskets or the wee brass block on the slider mechanism. There is no need to mark anything as the pump is manufactured to standardised parameters and the diesel shop will service it and re calibrate it to these.

It may be necessary to tweek things when the pump is replaced on the engine. The timing should be checked and also there is a suel adjuster screw inside the governor housing which might need tweeking if the engine is either too slow on pick up or speeds up with smoke.

Below is a typical diesel shop in Florida however you will find others using google and words such as bosch fuel injection service atlanta or whatever area you wish to search .

SW Florida Bosch

Everglades Diesel Injection Service Inc, Fort Lauderdale FL 33315

[Bambolera]

Thanks everyone for your thoughtful responses.

The pump has been in the shop for the past week. They are still looking for the third replacement piston (so far, they have found one in the US and one in Germany). Apparently, the pump was in need of service; the guy said it was corroded. The boat has been sitting for over a year without use. What would cause the injector pump to corrode?

It seems strange, because I had the engine running for a few hours, just the day before, without so much as a hiccup. The next day, it wouldn't start?

[shakey doug]

D'day,
Water or to much petrol in fuel.

[Bilgediver]

Originally Posted by Bambolera

Thanks everyone for your thoughtful responses.

The pump has been in the shop for the past week. They are still looking for the third replacement piston (so far, they have found one in the US and one in Germany). Apparently, the pump was in need of service; the guy said it was corroded. The boat has been sitting for over a year without use. What would cause the injector pump to corrode?

It seems strange, because I had the engine running for a few hours, just the day before, without so much as a hiccup. The next day, it wouldn't start?

I suspect the problem that stopped it was a stuck delivery valve. The plungers should be available in Europe.

Yje corrosion could be due to excess water in the fuel or bugs. Suggest you clean out the fuel tank to remove any water sitting on the tank bottom. Did you check the filters?

[FlyingCloud1937]

Originally Posted by Bilgediver

I suspect the problem that stopped it was a stuck delivery valve. The plungers should be available in Europe.

Yje corrosion could be due to excess water in the fuel or bugs. Suggest you clean out the fuel tank to remove any water sitting on the tank bottom. Did you check the filters?

For the record the actual engine is a Shibura/Perkins/Cat and all of the engine parts are PERKINS/CAT.
Volvo just marinizes the Perky/Cat and calls it a Volvo.

the fuel pump issue is a result of the low sulfur diesel....any diesel today needs a concentrated standyne additive run through the pump/injectors before left alone.

lloyd

[Bambolera]

Originally Posted by Bilgediver

I suspect the problem that stopped it was a stuck delivery valve. The plungers should be available in Europe.

Yje corrosion could be due to excess water in the fuel or bugs. Suggest you clean out the fuel tank to remove any water sitting on the tank bottom. Did you check the filters?

The quote for repair is $1,200. Damn! I wasn't expecting that...

Maybe I can find a used pump off an old engine?