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Volvo d2-40 fuel leak


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Hi all,

 

My engine is leaking fuel from around the injection pump. It varies from none at idle to a steady drip under load at cruising rpm. A quick look at the injection pump tells me it's bolted on using unusual bolts with 5 sided heads. I presume this is Volvo's way of trying to tell me I shouldn't pull it off myself.

 

Does anyone have experience with these? Are there likely causes? If I can locate a 5 sided socket in the right size and remove it is this likely to reveal anything, or is it normal to have to replace the pump?

 

Cheers

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Pump is serviceable, new is very expensive - several thousand.

Servicing is a specialist job - the volvo dealers wont do it, they'll outsource it.

If you are happy that you can correctly setup the injection timing, you can certainly take it off and send it to a diesel pump specialist for repair.

If you search this site for "injection pump" you find the names of a few service oufits..

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raz88 are you absolutely sure the fuel is coming out of the pump ?

I’d think it’s more likely to be from an injectors line either cracked or not seated properly or even slightly loose.

If motor is running ok it must be on the pressure side eg not the feed side or you would be sucking air.

I’d be giving it a really good clean with degreaser and run it up to revs whilst watching it with a torch.

Worth a try anyway as injector pumps can be very tricky and expensive

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Not familiar with volvo but if it has a manual primer pump for bleeding, the diaphrams are notorious for getting holes in them. Ignore this if the pump is not part of the injector pump. You might see a change in your engine oil too as the diesel runs down the inside of the block poluting it.

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Thanks all.

 

Jon, it runs fine so you might be on the money. I will get some degreaser and have a good look for leaks coming from the high pressure side.

 

CH the bleed pump is a separate unit.

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One minor point of note, have realised the engine is actually an md2040, not a d2-40 as I'd said above.

 

Gave it a good clean and went leak hunting on the weekend.

 

On the outside of the injection pump there are 3 pipes that head off to the injectors. These each go through a pair of locknuts, then each goes through a small oval plate that boots on to the casting that is the outside of the pump.

 

The fuel appears to be leaking out from between one of the oval plates and the casting. Is it reasonable to try and remove theses plates and reseal? Or is taking them off effectively opening the pump and going to be very complicated?

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Photo? If the injector fuel lines "have left the pump" as in going from the injector pump to the injectors then that plate is only to hold then in place. You need to remove all the fuel line mounts an undo the olives at each end of the line, take it away and get a new one. These lines a under high pressure, you wont be able to repair them and even seeing where the leak is will be a mission as it will only appear under pressure. When you get your new injector line, put a bit of flat rubber under the plate before tightening them up. Engine vibration has most likely worn through or fractured the line, the rubber stops that. Personally, I would leave the plate off altogether if the lines are not too long. Wont effect the seal at the olives.

 

While I think of it. If your engine bay is accessable from above and not from the end you may find someone has stood on the motor and bent the injector lines! I've seen mechanics do this getting in and out of the engine room!

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As crazy said

Photo would be very helpful but sounds like cracked injector pipe

As said above if it’s just the pipes then remove them and take to diesel injector pump repairer, they will be able to pressure test them and make new ones as required.

The leak will be very small and the motor will run ok still, but this will get worse over time as it’s under very high pressure.

Hopefully this will be a lot cheaper repair than a leaky pump.

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I stupidly didn't take a photo of it while there yesterday, but found a photo online of the same motor. Leak is where the red arrow is pointing - from under the base of the oval plate that the "olive" sits on top of. Doesn't appear to be coming from the line itself.

 

The oval plate is held on by a bolt either side of the olive with a 5 sided head (not the usual 6) meaning it needs a special socket to get it off.

 

Thanks

IMG_20190114_095120.jpg

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Had a look on line. It's all one unit? Best bet, ring a volvo agent mechanic. Geoff at Whangarei Marine is a good bloke to try. 094383296 or 02102506789

 

I did suggest backing off those bolts to see if there is a large spring in there then thought better of it so deleted it. I did find a pic on line DONT!

8936.png

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So had a mechanic in who has confirmed it is the pump leaking, not the lines. Estimated $1700 to remove, send for repair and reinstall.

 

Does this seem reasonable to people here? Having not done timing of injector pumps before im not feeling confident about doing it myself...

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It’s not reasonable but it’s money well spent and the alternative is replacing the motor.

Are there any other things that could indicate that it’s getting to the end of its life ?

If not then it’s your best option

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