Injection pump removal

[taz2]

Hello, sadly the injection pump on my westerbeke 4 108 diesel engine has to be removed, due to it not functioning as it should. It is not pushing fuel to injectors, 2,3 and 4.

The engine will only start when the lift pump is used then dies. I had a mechanic come out try to get it to run. The engine responded as with all the other previous attempts. Starts, after a few seconds dies.

The mechanic and I concluded fuel starvation as the fuel pump is not working and would need to be removed, rebuilt or replaced.

My question is, has anyone removed their fuel pump and if so what should the I be looking out for? Someone mention something about making sure "timing" is correct and that the engine needs to be in the correct position! How can this be done if the engine cannot run?

Need help please.

[marcjsmith]

Taz, I've done this on my Perk 4108. timing is an issue. if you don't have any timing marks on the engine and pump then you will need to make your own. to ensure that you get the pump back to the original setting if you are rebuilding your existing pump. which I did

there is no way to install the pump incorrectly since the shaft is keyed. it can only go in one way.

not the most difficult job it is tucked under the ex manifold so I removed my ex manifold and heat exchange to make it a bit easier

I did have some issue getting the engine restarted as even though I was very careful I had moved my throttle adjustments and the stop adjustment. so it took some doing to get that set back for a good idle.

you do not have to remove anything from the front of then engine three bolts on the three corners of the pump flange. is what hold it to the engine.

[taz2]

Thank you. Thank you, thank you. Your response is greatly appreciated. My pump is under the coolant manifold, I'm thinking of removing the manifold myself for the experience and get the mechanic to remove the pump. Your thoughts!

You mentioned rebuilding the original, how easy was it or did you have a fabricator rebuild it? The mechanic mentioned that it cost $600, which made me a little uneasy. Newbie on a budget.

[taz2]

Is there a repair kit?

[marcjsmith]

I rebuild mine myself.
I sent you a PM

[capt jgw]

Don't try to rebuild it yourself, even truck and tractor repair shops don't mess with injectors, they send them out to a specialist diesel injection shop. Most larger cities should have one. I used Diesel Injection Service once and they were very good and I though reasonably priced for what they did. I believe it's a big chain operation so there should be one or an equivalent near you. Your mechanic should know what's in the area.

[taz2]

Thank you very much, there is a company in Anne arundel the mechanic mentioned. Is it possible for me to be a to remove the pump or the mechanic take it off? Need to keep the cost down to pay for the rebuild.

Thank you again. I feel a lot better knowing this.

[capt jgw]

Should be pretty easy, the pump on my Kubota was dead simple. As mentioned earlier make your own index marks on the pump and where it mounts so you can get the timing right. Scratch or punch it in deep on the pump as they'll likely remove the paint, you need the mark to survive that. Actually there should already be a mark there but it may be covered in paint. I have Perkins 6.364's in my trawler and I can't see the marks but the manuals say they're there.

[marcjsmith]

Taz,

When I rebuilt my pump my issues were at the throttle body area and the transfer pump vanes. I did not have to split the case open

[taz2]

Morning Marc, im trying to locate your PM, as I'm with a fellow sailor attempting to remove the pump.

I cannot locate your PM with your number.

Taz

[taz2]

Thanks guys. I managed to remove the fuel pump. It took longer than I thought. I also managed to wipe away the paint from over the serial and model numbers/ information.

My fuel pump is mechanically governed, I do not have any knowledge, therefore I will send it out to be rebuilt and take the hit cost wise. I shall be conducting further research on the pump just to better educate myself.

I will let you know how things go once the pump is rebuilt and reinstalled. (another challenge due to lack of space and access).

[skipperpete]

Thanks for the update Taz2, good work getting the pump off , that inside nut on the baseplate can be a bit of a trial on the mechanically governed pump. You should get the injectors pop tested, it’s a rare event but a leaking injector nozzle can affect a CAV DPA pump in the way you describe, the compression can make its way into the injector body and back up the pipe, there are no delivery valves in DPA pumps and a disturbance like air in the pipe can upset the delicate balance of pressure that makes the pump elements refill after injection. Hope the tab for the pump service isn’t too steep and she runs like a dream when you put it back on.

[taz2]

Thanks, the tab I'm going go guess will be close to $700, which leaves a terrible feeling.

I approached A.diesel in Anna Rrundle. I need to look at any other options based I'm annapolis or upper malbough.

[skipperpete]

The cost estimate for a DPA rebuild usually includes the hydraulic head (rotor) and thats about half of the pump. Labour costs for injection techs are very high, their workshop typically costs $500,000 to over a million for the equipment alone and the training, skills and availability of staff is another difficulty, these techs are not just plain ol diesel mechanics.

[Wotname]

Originally Posted by skipperpete

Thanks for the update Taz2, good work getting the pump off , that inside nut on the baseplate can be a bit of a trial on the mechanically governed pump. You should get the injectors pop tested, it’s a rare event but a leaking injector nozzle can affect a CAV DPA pump in the way you describe, the compression can make its way into the injector body and back up the pipe, there are no delivery valves in DPA pumps and a disturbance like air in the pipe can upset the delicate balance of pressure that makes the pump elements refill after injection. Hope the tab for the pump service isn’t too steep and she runs like a dream when you put it back on.

Great information + great detail + great explanation of an obscure occurrence = a very worthwhile post.