Westerbeke 4-91 Injection Pump Leaking

[marvinjansen50]

I have a 1975 Glander Tavana 33 with a Westerbeke 4-91 engine that runs great. the problem is fuel leaking out around the throttle shaft it seems. Any suggestions on how to repair?

[model 10]

If it's a CAV pump, it's a piece of cake. Don't remember the exact details but it was easy with just a couple of screws and a new O ring. The shaft might be worn so it's not a long term fix.

[a64pilot]

I was thinking, pull it and have it overhauled. At almost 40 yrs old there has to be a lot of seals either gone or fixing to go, I have seen rubber get old and hard and begin wearing steel away too, crankshaft seals for instance

[marvinjansen50]

Guy, I like that I may be able to just replace an o ring on the shaft. Wonder if I can do that without removing the pump? Checked on getting one rebuilt and it is around $600 local at Test Calibration here in Mobile, or at Hanson's in MA. Hanson's seemed to be able to fix a worn shaft if that is the problem. I will try to just repair it myself. I did replace a large o ring in my old VW diesel and it worked fine afterward.

[model 10]

It would depend on your access of course but if you can see it and get your fingers on it ,should not be a problem. I found getting the cotter pin back in the throttle linkage to be the hardest thing.
About a year later before setting out on a cruise I had our pump and nozzles overhauled ($1000), and they replaced that shaft as part of the overhaul.
Cautionary note, about another year or two later, running the reef off the north side of Cuba, the throttle arm came loose on the shaft. We could only get about 1700 rpm. I had not tightened the arm on the shaft enough. Pretty small bolt but you gotta be brave and get it tight.

[HappyMdRSailor]

Originally Posted by marvinjansen50

I have a 1975 Glander Tavana 33 with a Westerbeke 4-91 engine that runs great. the problem is fuel leaking out around the throttle shaft it seems. Any suggestions on how to repair?

Marv, take a picture so we can confirm...

Originally Posted by Guy

If it's a CAV pump, it's a piece of cake. Don't remember the exact details but it was easy with just a couple of screws and a new O ring. The shaft might be worn so it's not a long term fix.

Agreed if it's a CAV... and I'll bet he can get the cover off in place to do it...

So... we wait for a pic...

[HappyMdRSailor]

Like this one?

[marvinjansen50]

don't think it looked like that but may look different with linkages and lines. will look for a pic of one like what I remember.

[marvinjansen50]

I think my linkage arms or on the sides

[marvinjansen50]

I am trying to put on a pic from the parts list manual

[marvinjansen50]

tried again using attachment, used add video last try

[HappyMdRSailor]

Not sure on this style, but I think you should be able to get the top housing off without removing the pump... When you get to the boat, see if you can read the data plate on the pump... We'll find an answer!

[sanibel sailor]

On mine, there are 2 bolts holding the throttle housing in place. Pull the throttle and kill cable, then the bolts. They will be safety wired. I have seen both regular hex bolts as well as 12 sided head, they are 1/4", be prepared with a correct wrench or socket. The housing will lift straight out. I was not able to easily disassemble mine, but I did not try hard as the shaft was not leaking. I got lucky and picked up a seal kit for $17 on eBay, they are usually about $30.

[marvinjansen50]

I went out to the boat today and looked for any name or numbers and couldn't find any but did take some pics and also put a container under it to catch the fuel leaking. I ran it for about a half hour or more working on the alternator and it only put an inch or so in the pan. Needs fixing but not urgent. Did notice leak is definitely from the throttle shaft. Still open to what to do.

[sanibel sailor]

your number plate is not in the areas shown. It is on the opposite surface as shown in the first 2 pics, aft side on housing, deep to the banjo bolts, kind of under where the throttle lever is. It probably has been painted over.
It will read:
CAV DPA
Model 3246F857
Ser 3186XU (I think this is the series rather than a serial number)
Settings 421/1050/0/4400

Settings are for rebuilders