Volvo Penta 2003T Injector Pumps

[Snowpetrel]

If you put a jerry can in the cockpit and gravity feed. It works without a pump of any sort!

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[Rustic Charm]

Originally Posted by Snowpetrel

If you put a jerry can in the cockpit and gravity feed. It works without a pump of any sort!

Sent from my SM-G930F using Cruisers Sailing Forum mobile app

Well, that worries me because we did that when the mechanic was trying to get it to go and we couldn't get fuel to the injector pumps.

[El Pinguino]

So...what lay between the jerry can and the injector pumps?

Fine filter full of crud?
Lift pump?
Primary filter?

The logical place to hook in a system like that is before the primary filter..

[Snowpetrel]

Maybe it doesnt work with all types of injector pumps. Certainly worked fine with my old isuzu. Maybe there was a blockage somewhere?

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[Rustic Charm]

Well, I'll get a cheap $13 electric pump and try to by pass it and try that first. Overhauling the pump looks like it's about $200 for a repair kit. Considering it's basically just a diaphragm I think that's rediculous.

[shakey doug]

A lot of cheap in line fuel pumps require a Positive Head they are not able to prime if a vacuum lift is required.

[Snowpetrel]

RC, would you be able to run us through exactly what the Mechanic tested and how the engine died in the first place?

Sounds like we might become missing something simple. Eg has the fuel shutoff solenoid failed with the rack closed? Could there be a blockage in part of the line. Are the injectors getting any fuel and have they been properly bleed? Does the engine need glow plugs and are they working?

You have got me curious now! Not that I am much of an engineer and I dont know those engines, but if it isn't the injector pump what is it?

[markpl]

1, You have to check fuel pump functionality,
is very simple,
2, if pump not working you have open this pump(cost you nothing)
very possible one of the pump valves are not working,
again is very simple,
3, follow fuel flow, next step is small bolt on top of the second filter,
loose slightly, when pumping fuel air will escape thru this bolt,
4, take you time
2001, 2002, 2003/T are fully analog engines, no magic there,

one more thing very important!!!, injector pumps have small pin,
this have to be engage proper way with bar inside the engine.

[Rustic Charm]

Originally Posted by Snowpetrel

RC, would you be able to run us through exactly what the Mechanic tested and how the engine died in the first place?

Sounds like we might become missing something simple. Eg has the fuel shutoff solenoid failed with the rack closed? Could there be a blockage in part of the line. Are the injectors getting any fuel and have they been properly bleed? Does the engine need glow plugs and are they working?

You have got me curious now! Not that I am much of an engineer and I dont know those engines, but if it isn't the injector pump what is it?

What happened -
At about 90 miles from home I could hear the engine struggling and then cut out. Sounded immediately like fuel starvation. I changed the filters and off I went. Immediately noticed fuel was very dark in the Rayco. The main Raycor filter was very black and clogged. Of my 200 ltr tank I did a dip stick check and I was down to about 90 ltrs.

Over the next 80 miles same thing happened. I changed the filters twice more. I decided that if I can get to 10 miles I'd change the fuel to a cleaner fuel source.

I got to about 10 miles and it cut out again. This time I got my 20 ltr heater tank out, which is a Jerry can and disconnected the two fuel lines to the keel tank. I changed the filters again, for the final time and set off. The engine not only went well, but picked up a Knott of speed. Sounded much better.

Once I reached the Tamar River where I arranged to pick up some extra fuel, I pulled up to the dock, popped the gear into reverse to halt it and it stalled. Then I was unable to get it started again.

Mechanic
Next day the mechanic came. He started from the tank (Jerry can) and moved forward. The Jerry can was put on a shelf above the motor. He checked the first Raycor filter to make sure fuel was flowing, then to the primary filter and then to the lift pump. (I think that was the order). Then he cracked the injectors and there was no fuel to them. So he then checked the first injector pump 'in' and there was fuel. But when he checked the over flow, there was none. Which is why he concluded the pumps were the problem.

I'm thinking now that he might have received a little fuel out of the lift pump but not enough to go through the injector pumps.

He then got me to spray Areo start into the air filter to test the engine and it started without a problem first time. I did it again and this time whilst I was spraying the Areo start in and the motor was going I 'think' he cracked an injector pump again. At least I think that's what he was doing. I was in the back with my feet in the air.

[shakey doug]

I SAY AGAIN. Take top of lift pump and clean fine mesh filter.

[Rustic Charm]

Originally Posted by shakey doug

I SAY AGAIN. Take top of lift pump and clean fine mesh filter.

Yes, I'm going to try that. I couldn't get to my boat this weekend. Possibly tomorrow. But, that's the first thing I'm going to do.

[shakey doug]

I'am hoping its the early series pump that can be opened up. When using the jerry can was it still routed thru lift pump?

[Rustic Charm]

Originally Posted by shakey doug

I'am hoping its the early series pump that can be opened up. When using the jerry can was it still routed thru lift pump?

It is yes. with the nut on the top.

And my local VP dealer today has advised he can get a kit for it for only $119

[Snowpetrel]

Thanks for the info RC, hopefully Dougs tip solves the problem for you.

One other question, when you jury rigged the jerry can to get you into the tamar was it at floor level, or higher? It certainly would have helped the fuel pump get presure to the injector pump.

[Rustic Charm]

Originally Posted by Snowpetrel

Thanks for the info RC, hopefully Dougs tip solves the problem for you.

One other question, when you jury rigged the jerry can to get you into the tamar was it at floor level, or higher? It certainly would have helped the fuel pump get presure to the injector pump.

When I rigged it in the first place I had it on the floor, so below the engine. When the mechanic was trying to get it going we had it on a shelf above the engine.