Volvo Penta 2003T Injector Pumps

[El Pinguino]

Originally Posted by Rustic Charm

No, they are the pumps. There's three pumps and three injectors. The injectors are on the stern side of the engine and the pumps are on the port side.

I see said the blind man... mine just has the single pump serving three cylinders.

I'm surprised fuel as bad as you say it was was able to get past two filters and as far as the pumps..

[Rustic Charm]

Originally Posted by El Pinguino

I see said the blind man... mine just has the single pump serving three cylinders.

I'm surprised fuel as bad as you say it was was able to get past two filters and as far as the pumps..

The same thing the mechanic said. He thought it would more likely be 'water' that would have caused damage than fouled fuel.

[Dsanduril]

I think you may have to take apart the bottom end of the pump, that is the key part of the pump's timing. As the piston in the low end rises it rotates, opening and closing the intake and return ports. Scoring or damage there can lead to a short-circuit to one of the other ports rather than high pressure to the injector end. Great care in re-assembling to get the rotation of the piston exactly the same.

A couple of possibly useful resources:

https://www.youtube.com/watch?v=o9SFdAxf1Fc

The PFR is pretty similar in operation to the PFE used in the 2003.

This manual is for an engine that uses the same pump:

http://www.liberatedmanuals.com/TM-5-4320-313-14.pdf

Section 5 has a little more detail than the Volvo manuals. Not a great manual, but sometimes looking at other pictures/notes helps pull things together.

[sartorst]

Will your engine run at all ? I seriously doubt that all pumps would have failed at the same time . Before you get your fuel system back together and a source of good fuel try to get some oil in the cylinders through the injector holes spin the engine over to spread the lube through the cylinders, many time with all the bad fuel that did not ignite will cranking the cylinders become so washed that it will not start particularly if older
Get the fuel system bled as well as possible, get some heat in the intake (I don't think you have glow plugs) make sure the battery's are fully charged and spray WD40( if you have that)in the intake and run the engine on it until the fuel system takes over again once the engine is running then you can make a better assessment on what components are needed . Remember you are the fuel supply so don't over rev and don't use ether based products unless you absolutely have to
After seeing that surface in the pump I may have to retract the 600 grit statement that does look like water damage and you have not taken it apart all the way yet

[shakey doug]

The valves in the top of pump are the delivery valves if they visually show signs of damage they are knacked. They come as matched pairs not to be mixed up. When subjected to dirty fuel, particularly contaminated with water the mating surfaces score. Defective d/valves cause retarded fuel timing and pressure loss in some cases below the injector crack off pressure, this may be your units problem. These valves generally give up before to much damage occurs barrel & plunger, leave the valves out and replace the holder nut, then crank the engine at full throttle noting the flow, if a constant pulsing flow appears the barrels may be serviceable.


Diesel injection services. Darcy st, West Hobart. Will be able to help parts.

[El Pinguino]

If indeed it was a water issue I would be rather worried about the origin.
I recall that it is a 200 litre tank and that it was half full when this happened.

Either an awful lot of water in the diesel you have taken since the big overhaul or it is entering 'from sea'.

If you open the inspection port and draw from the bottom what do you get?

No point fixing stuff if you are just going to suck up more of the same.....

[Rustic Charm]

Well, this is annoying. I took the three pumps in to a pump specialist who rang me today to advise there was nothing wrong with them. He's given them a basic service and tested though.

So, now I'm down to the lifter pump that is the problem. I might get to pull that out in the weekend.

[Paul L]

Use a cheap electric pump and ignore the mechanical one.

[Rustic Charm]

Originally Posted by Paul L

Use a cheap electric pump and ignore the mechanical one.

I like that idea if it can be done just to get me going. All I want to use the engine for is getting me back and forwards to the jetty. I'm looking at a new engine overall.

Do I have to bypass the current mechanical pump? I suspect the diaphragm is broken and oil is mixing with the fuel.

[El Pinguino]

Originally Posted by Rustic Charm

So, now I'm down to the lifter pump that is the problem. I might get to pull that out in the weekend.

I've had the diaphragm fail in two of them on my MD17D..... the first after about 20 years... the next after 20 years ( or at least 16 ) storage and 7 years use.... is rubber so is age related as much as hour related.

[El Pinguino]

Originally Posted by Rustic Charm

I like that idea if it can be done just to get me going. All I want to use the engine for is getting me back and forwards to the jetty. I'm looking at a new engine overall.

Do I have to bypass the current mechanical pump? I suspect the diaphragm is broken and oil is mixing with the fuel.

If the diaphragm is shot it just won't be lifting diesel from the tank..there is no oil/dieso interface..

[Rustic Charm]

Originally Posted by El Pinguino

If the diaphragm is shot it just won't be lifting diesel from the tank..there is no oil/dieso interface..

Looking at the drawing for it, if the diaphragm has a large enough crack or hole, it would also let oil into the fuel wouldn't it? Through the lifting mechanism that looks like a ram.

[Paul L]

If I remember correctly there were two versions of the pump. One had a bleed hole under it that leaked on failure, the othet leaks into the oil. If you have diesel getting pumped into the oil it should be obvious in the oil. Try an electric pump on the pickup line alone, if that doesn't help then reroute to the hard pipe that exits the mechanical lift pump.

[El Pinguino]

Originally Posted by Rustic Charm

Looking at the drawing for it, if the diaphragm has a large enough crack or hole, it would also let oil into the fuel wouldn't it? Through the lifting mechanism that looks like a ram.

I'm assuming that it is similar in form and function to mine.... mine is gravity feed... so when it failed ( 1st time) the engine still ran but fuel free flowed into the bilge.

If it is actually lifting your fuel from where ever it just won't be lifting anything.... if working then on lower side of the diaphragm should be fuel... on the top - air...

[El Pinguino]

Mine looks like this.. Volvo Penta Fuel Lift Pump

The tongue on the left is what I would call the actuator.. is inside the engine in 'air'... no oil in that bit...