Should I be scared of taking my Volvo Penta 2003 injector pumps apart?

[kenbo]

Originally Posted by jimbunyard

I've had plenty of injection pumps apart for cleaning, with no ill effects, but not those from a 2003. Cleanliness and patience are the most important things to observe here. If the engine is running fine now, there's no reason to not think it will afterwards, if you get everything right.

For those unaware, the 2003 series has unit pumps; each supplies it's own injector.

If you have reasonably good mechanical skills, you have a reasonably good chance at success. Looking at the exploded view below, I'd guess that part of the pump might be spring loaded, but a careful assessment before you start taking things apart should enable you to keep things from flying everywhere.

At worst, you'll have to face the embarassment of bringing them to the specialist with one of them in pieces.

If someone with hands-on experience with this specific pump is reading, now's your time to speak up with contrary cautionary advice...

Very similar design to the Zexel Bosch pumps used on Kubota's that I am familiar with. The difference is that the Zexel is a unitary design for multiple cylinder engines.

[kenbo]

Originally Posted by sandy stone

https://www.google.com/url?sa=t&source=web&rct=j&url=https://www.marinedieselbasics.com/wp-content/uploads/Volvo-Penta-Type_2001-2002-2003T_Workshop-Manual.pdf&ved=2ahUKEwiMr6XW_L3qAhULi6wKHWIVBscQFj ABegQIAhAB&usg=AOvVaw3wF78X51GmUzaOkPBZmSY4

Disassembly step 5, reassembly step 15. Doesn't look like rocket science to me.

It's not at all. If it were my pump I'd replace the plunger and check valve as well if the parts were available. And I'd do both pumps since the VPs are not unitary. Don't do one and not the other for obvious reasons.

[Brewgyver]

Jim, do you have the index to go with the exploded diagram?

[jimbunyard]

https://www.marinepartseurope.com/en...23-11668C.aspx

[j.g.evans]

I have rebuilt Yanmar injectors with good success. I did have them pop tested by a local dealer and sometimes had to add or substitute shims. I soaked the parts in carburetor cleaner for a day or more and polished the piston with metal polish and gently cleaned the orifice with a tooth pick. I am sure all this was wrong but it worked.
Volvo injectors are so expensive, about 4x Yanmar, so I would go for it.
If you want them rebuilt, I believe you can get them done in FL for a lot less. Unfortunately I was never able to find a Bosh cross reference to my Volvo injectors.

[kenbo]

Originally Posted by jimbunyard

https://www.marinepartseurope.com/en...23-11668C.aspx

I see that the delivery valve is out of production, bummer. That's critical, if it leaks you won't get full fuel delivery with each stroke. Hope the OPs are still good.

[jimbunyard]

Originally Posted by kenbo

I see that the delivery valve is out of production, bummer. That's critical, if it leaks you won't get full fuel delivery with each stroke. Hope the OPs are still good.

If Volvo didn't make the pump, they may be available from whoever did. A knowledgable technician should know the answer to both questions.

[kenbo]

Originally Posted by j.g.evans

I have rebuilt Yanmar injectors with good success. I did have them pop tested by a local dealer and sometimes had to add or substitute shims. I soaked the parts in carburetor cleaner for a day or more and polished the piston with metal polish and gently cleaned the orifice with a tooth pick. I am sure all this was wrong but it worked.
Volvo injectors are so expensive, about 4x Yanmar, so I would go for it.
If you want them rebuilt, I believe you can get them done in FL for a lot less. Unfortunately I was never able to find a Bosh cross reference to my Volvo injectors.

I agree, injectors absolutely need the specialized equipment to pop test, spray pattern and drip. Plus they are subjected to much harsher environment than the injection pump.

[kenbo]

Originally Posted by jimbunyard

If Volvo didn't make the pump, they may be available from whoever did. A knowledgable technician should know the answer to both questions.

I'm sure you're right but I'm not familiar with older VP. I did work on a MD2030 another Japanese based diesel. Very smooth runner.

[sandy stone]

The injectors are Bosch, and I'm pretty sure the pumps are, too.

[Ken Z]

Dont do it . Take it to a good rebuilder, it is a precision part.

[BlackHeron]

The pumps are Bosch. Says Bosch right on the little placard. Any injector shop should be able to fully service them. Expect to pay about $200/each -one for each cylinder. Dont mix up the shims or their placement on the cylinders. Each pump and location has different tolerances from the factory and it takes a special tool from Volvo-Penta to gauge them onto each cam to determine which shom to use.

[DougR]

Scared.....no, but careful, attentive, and clean.

If you have external fuel leaks, there are only three places where it could be coming from, and these are:

1. The banjo fittings where the fuel hoses attach to the outside of the pumps. There are four copper washers per pump, two per hollow screw, so get a handful of washers and change the washers on all for pumps.

2. The fittings where the high pressure fuel pipes attach to the injection pump. Make sure the pipes aren’t bent slightly and check that the tapered fitting on the end of the pipe is not scratched or dinged and that it’s sitting squarely in the retainer (#6).

3. The O ring (#8) that is fitted on the delivery valve retainer (#6) could be hardened or otherwise compromised causing the weeping. Changing this O ring is a walk in the park, but as mentioned you need to be attentive when doing it.

My suggestion is to not remove the injection pump from the engine block when doing this, it’s not necessary if you have reasonable access, but you might remove the fuel feed hoses if they are in your way. Clean up the area around each pump, remove the high pressure pipe and unscrew the delivery valve retainer (#6) a few turns until the O ring starts to be visible. Then clean up the cracked paint chips that have showed up and slowly continue to unscrew the retainer. When the retainer is completely unscrewed and free you can carefully lift it off of the pump body and the springs, etc. will sit in place. Now you can replace the O ring and the assembly process is the reverse of disassembly.

It wouldn’t hurt to place clean rags or similar around in the event that the delivery valve spring sticks in the retainer, but normally that doesn’t happen.

[roland stockham]

Givent that you seem confused by the basic parts terminology I would say no The injectors, one per cylinder, distribute high pressure fuel by spraying it into the cylinders. They must meter the correct amount in the right spay pattern to ge the engine to run smoothly and evenly. Cleaning them and replacing the seals between the injector and the fuel lines is a DIY job. Servicing them is not. The high pressure pump, one per engine, controls engine speed and creates the fuel pressure the injectors need. They are super sensitive to even the smallest grit particles which will rite off the pump (that's also why you have multiple filters on the fuel lines) They are serviced in a clean shop. By clean I mean clean as in like a hospital surgery, dust proof room, filtered air, everyone in paper suits and hair nets etc. So no, not DIY

[kenbo]

Originally Posted by roland stockham

Givent that you seem confused by the basic parts terminology I would say no The injectors, one per cylinder, distribute high pressure fuel by spraying it into the cylinders. They must meter the correct amount in the right spay pattern to ge the engine to run smoothly and evenly. Cleaning them and replacing the seals between the injector and the fuel lines is a DIY job. Servicing them is not. The high pressure pump, one per engine, controls engine speed and creates the fuel pressure the injectors need. They are super sensitive to even the smallest grit particles which will rite off the pump (that's also why you have multiple filters on the fuel lines) They are serviced in a clean shop. By clean I mean clean as in like a hospital surgery, dust proof room, filtered air, everyone in paper suits and hair nets etc. So no, not DIY

Ronald,
No offense but you are the one who is confused. Inline HP pumps have one pump per cylinder or injector. You are describing a rotary HP pump. Different design and much less complex.