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Old 30-08-2014, 18:29   #16
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Re: westerbeke 4-91 injection pump leaking

I didn't get a pic of the area where the plate may be. Question, does the pump timing adjust by twisting the pump and then tightening it down? It runs so good now I hate to mess with the timing, but would be easier to do repair with it off the engine. How do you set timing or is it an "ear" thing? My old VW was done with a dial indicator and fairly complicated but I got it right more than once.
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Old 30-08-2014, 20:24   #17
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Re: westerbeke 4-91 injection pump leaking

Either leave the pump mounted to the crankcase and pull the throttle housing (would be my choice) or mark the pump's position and pull the 3 nuts to remove the whole thing. To pull the pump, you will need to detach the fuel lines, electrical wires also.

Timing is set by rotating the pump relative to the crankcase, kinda like rotating the distributor to adjust ignition timing on a Bug. (John Muir started me down this wrenching path). I have tweaked the diesel timing by guess and by God when mine was hard starting after a rebuild.
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Old 31-08-2014, 17:30   #18
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Re: westerbeke 4-91 injection pump leaking

Here is your sign, so to speak
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Old 31-08-2014, 17:32   #19
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Re: westerbeke 4-91 injection pump leaking

Close up of housing, my bolts are 12 point
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Old 31-08-2014, 17:34   #20
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Re: westerbeke 4-91 injection pump leaking

Actually that was my socket, had to get it on eBay, not easy to find
Here is the housing
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Old 31-08-2014, 17:36   #21
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Re: westerbeke 4-91 injection pump leaking

Cut the wires, the bolts have a seal on them.
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Old 31-08-2014, 17:37   #22
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Re: westerbeke 4-91 injection pump leaking

Pull the bolts
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Old 31-08-2014, 17:41   #23
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Re: westerbeke 4-91 injection pump leaking

And out she comes, just pull strait up, put tape, then something like a rag over the hole, imperative to keep crud out of the innards, that is the precisely machined parts in there.
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Old 31-08-2014, 18:19   #24
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Re: westerbeke 4-91 injection pump leaking

Thanks for pics. Looks like mine. What size is the socket?

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Old 31-08-2014, 20:00   #25
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Re: westerbeke 4-91 injection pump leaking

I wonder if there is a seal on the throttle shaft?
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Old 01-09-2014, 04:42   #26
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Re: westerbeke 4-91 injection pump leaking

mine is 1/4" socket, yours looks like a standard hex cap rather than the 12 point. Most of these small sockets are 6 point.

I believe there is a seal on the throttle shaft. I have not disassembled mine. I cannot find an exploded diagram of it.

Here is a link to the pump manual, most of it does not apply to you, but nice to have.

Cav dpa Pump Rebuild Manual
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Old 22-09-2014, 14:53   #27
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Re: westerbeke 4-91 injection pump leaking

I pulled the top off the pump and found out I could have left it in and just pulled the throttle shaft out after I had removed the top bolt closest to the throttle cable. This would have been so simple. The o ring was worn and stiff. I went to the local injector shop and bought the kit to use 2 o rings, 2 bolt rubber seals, and one gasket, but also got some education along with it. A warning that if the throttle valve sticks from any dirt in it from the disassemble, the engine could get too much fuel and run away or over rev. I was warned to be ready to block off the air intake in case this happens. Also was warned that some of the internal seals go bad the fuel could get into the crankcase and when it gets high enough to hit the pistons it will run away. So, I will watch and if the oil gets mysteriously higher, will rebuild pump. May get pump rebuilt before I venture too far anyway. Will put it on tomorrow and figure out how to block off the air way is case of a run away.
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Old 22-09-2014, 15:34   #28
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Re: westerbeke 4-91 injection pump leaking

take pics? I have not done my throttle seal.

It is good to be aware of a runaway and be prepared for it, but sounds a bit like scare tactics. I guess it really depends upon how it is presented. My pump adventures began when the local shop declined to let me be present when they rebuilt it. Kind of left a negative impression. I did send one off to be rebuilt in Arkansas, only charged $325 I recall.
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Old 22-09-2014, 17:56   #29
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Re: westerbeke 4-91 injection pump leaking

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[ATTACH]88630[/ATTACH)
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Old 22-09-2014, 17:57   #30
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Re: westerbeke 4-91 injection pump leaking

Hope pics help. Ask any questions and I will try to answer.
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