Super sized injection pump LEAK!!!

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Re: Super sized injection pump LEAK!!!

Postby 93DodgeCummins » Wed Feb 06, 2013 4:27 pm

Found a kit on ebay. If you search for dgk-121 nothing comes up but if you search cummins injection pump gasket the kit shows up
93 Dodge W250 4X4, Custom air intake, Diamond Eye 4 inch turbo back straight pipe exhaust, HX-35W with Banks upgrades, KDP fixed, Getrag 5 speed, Isspro Tach, pyro, fuel pressure, and boost. Raptor 150, 3200 rpm spring, Power Screw in 1 turn, aftermarket fuel pin
93DodgeCummins
fuel screw!!!!
 
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Re: Super sized injection pump LEAK!!!

Postby 93DodgeCummins » Sat Feb 09, 2013 8:47 am

I think i found the problem... :roll: Now the question is do I just do a reseal or just replace that o ring and call it good... Also is there any good way to clean the IP case with out getting crap in the shaft area, inlet port, and the delivery valves?

Image
93 Dodge W250 4X4, Custom air intake, Diamond Eye 4 inch turbo back straight pipe exhaust, HX-35W with Banks upgrades, KDP fixed, Getrag 5 speed, Isspro Tach, pyro, fuel pressure, and boost. Raptor 150, 3200 rpm spring, Power Screw in 1 turn, aftermarket fuel pin
93DodgeCummins
fuel screw!!!!
 
Posts: 396
Joined: Thu Dec 03, 2009 6:50 pm
Location: Pickstown, SD

Re: Super sized injection pump LEAK!!!

Postby RCCUMMINS89 » Sat Feb 09, 2013 8:53 am

Replace the o ring and call it a day. Unless you are fairly mechanical and really know what you are doing, taking apart an injection pump can easily lead to problems.

But if you feel comfortable, google "ve pump rebuild" and some stuff will come up...usually on the vw forums, but it'll help.
89 RC on shortened 92 diesel frame - NV4500 w/dual disc/4.10s on 37s. - Self built pump, "hot screw", lots of timing, True high volume low pressure lift pump, 62fmw/68/.7gated, 77lpm SAC Inj., Studs/O-rings,- 423/1220 Mustang - 11/16/2013 http://www.TheHungryDiesel.com full line dealer, if you don't see it please ask.
RCCUMMINS89
14mm rotor
 
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Re: Super sized injection pump LEAK!!!

Postby Mark Nixon » Sat Feb 09, 2013 9:29 am

IF YOU FEEL COMFORTABLE, re-seal the whole thing.
Otherwise you'll be fighting leaks piecemeal, until you either fix them all, or get disgusted and do it right yourself, or buy a new pump.

The ones that are LIKELY to give the most fits are the KSB and it's accompanying rear cover 'O' rings (as you know), the AFC transfer pin and the throttle shaft 'O' ring.
To a smaller degree, the governor shaft seals and the KSB line 'O' rings fail, as well.
MOST guys who do a GS install end up re-sealing the top during the install, anyway.

I've done a few and even corrected other's foul-ups, so it's not a problem for me, but everyone is different.

Mark.
Mark Nixon
 
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Re: Super sized injection pump LEAK!!!

Postby RCCUMMINS89 » Sat Feb 09, 2013 9:37 am

Yep.,... I was told "I promise your truck will never run again if you open it up"

I am still so insulted by this, it makes me want to punch the injection pump shop guy in the face....every time I think about it.

Now saying that, I can easily see where one can make mistakes inside of the pump....THERE ARE ALLOT OF PIECES.

But if you go through the rebuild threads and feel comfortable, then you can do it. You'll know by looking at the pics.
89 RC on shortened 92 diesel frame - NV4500 w/dual disc/4.10s on 37s. - Self built pump, "hot screw", lots of timing, True high volume low pressure lift pump, 62fmw/68/.7gated, 77lpm SAC Inj., Studs/O-rings,- 423/1220 Mustang - 11/16/2013 http://www.TheHungryDiesel.com full line dealer, if you don't see it please ask.
RCCUMMINS89
14mm rotor
 
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Re: Super sized injection pump LEAK!!!

Postby Mark Nixon » Sat Feb 09, 2013 9:50 am

In my case, I had a seared parts pump that was basically complete, so I read a bit.
I was wanting to put a 3200 GS in my old DAMNCHARGER and heard the horror stories on the tophat and pin zipping into nothingness, so I decided to take apart a junk pump.
Best 3 hour learning experience I have ever had and it didn't hurt a good pump, in fact I eventually pieced the parts one out later.

Look at it this way, you can either tear it down and try to learn, fail and spend the money to get it fixed, or buy a new pump for X number of $$ and still have paid the same.
My money's on a learning experience that I do successfully and save a few $$ doing it.

"Education is PRICELESS, self education is INVALUABLE!" 8)

Mark.
Mark Nixon
 
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Re: Super sized injection pump LEAK!!!

Postby 93DodgeCummins » Sat Feb 09, 2013 11:04 am

Alright u guys have convinced me to do the whole thing. I have had just about everything else apart on the truck so why not haha. Guess I'm doing pretty good for only being 18!
93 Dodge W250 4X4, Custom air intake, Diamond Eye 4 inch turbo back straight pipe exhaust, HX-35W with Banks upgrades, KDP fixed, Getrag 5 speed, Isspro Tach, pyro, fuel pressure, and boost. Raptor 150, 3200 rpm spring, Power Screw in 1 turn, aftermarket fuel pin
93DodgeCummins
fuel screw!!!!
 
Posts: 396
Joined: Thu Dec 03, 2009 6:50 pm
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Re: Super sized injection pump LEAK!!!

Postby cmann250 » Sat Feb 09, 2013 11:57 am

93DodgeCummins wrote:Guess I'm doing pretty good for only being 18!

Yes, most kids these days have no motivation or mechanical skill.

I'm 19 by the way :lol:
Caleb, Certified Shade Tree Mechanic Extraordinaire :mrgreen:
The 1stgen.org black sheep

"Whatever!" - Coach Jerry Smith
cmann250
14mm rotor
 
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Re: Super sized injection pump LEAK!!!

Postby 93DodgeCummins » Sat Feb 09, 2013 7:41 pm

Here is the progress so far!

Image
93 Dodge W250 4X4, Custom air intake, Diamond Eye 4 inch turbo back straight pipe exhaust, HX-35W with Banks upgrades, KDP fixed, Getrag 5 speed, Isspro Tach, pyro, fuel pressure, and boost. Raptor 150, 3200 rpm spring, Power Screw in 1 turn, aftermarket fuel pin
93DodgeCummins
fuel screw!!!!
 
Posts: 396
Joined: Thu Dec 03, 2009 6:50 pm
Location: Pickstown, SD
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Re: Super sized injection pump LEAK!!!

Postby Mark Nixon » Sat Feb 09, 2013 8:01 pm

Oh boy! A bunch of parts! :mrgreen:

For ease of re-assembly, pay particular attention to the position of the cam plate in relation to the "crank" keyway..MARK IT.
It can go in 180* off and you wouldn't know it until you try to start it.

If you want to remove the bolts for the control levers in the main case, either make a socket from a 6 point 13mm socket, by grinding every other point off the socket (create 3 "fingers"), or lightly tap one corner with a SMALL chisel, then turn them out with needle-nosed pliers.

The AFC lever, in the top, is held in with a pin, which is secured by 2 steel balls.
You'll need to drive one in to drive one out, then drive the other one back out with the pin.
Might not be kosher, but it has worked for me and many others.

Mark.
Mark Nixon
 
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Re: Super sized injection pump LEAK!!!

Postby 93DodgeCummins » Sat Feb 09, 2013 8:22 pm

Is that Cam plate just behind the pump head? Also how do you remove the delivery valves? They seem to be super tight. I was thinking maybe just touch off an impact wrench on them but i don't know if that will hurt anything... I need to get my chunk of rubber from the fss solenoid out.
93 Dodge W250 4X4, Custom air intake, Diamond Eye 4 inch turbo back straight pipe exhaust, HX-35W with Banks upgrades, KDP fixed, Getrag 5 speed, Isspro Tach, pyro, fuel pressure, and boost. Raptor 150, 3200 rpm spring, Power Screw in 1 turn, aftermarket fuel pin
93DodgeCummins
fuel screw!!!!
 
Posts: 396
Joined: Thu Dec 03, 2009 6:50 pm
Location: Pickstown, SD
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Re: Super sized injection pump LEAK!!!

Postby Mark Nixon » Sat Feb 09, 2013 8:36 pm

Delivery valves are simple enough, just make sure you have a firm grip on the pump and a quick smack on a 1/2" ratchet should pop them loose.
Air is okay, with discretion.

The cam plate is the item with the dips in it that the rotor (plunger) sits into.
Also, beware of the itty-bitty (8mm) round spacer that sits between the cam plate and the plunger and DON'T LOSE IT!!!

Mark.
Mark Nixon
 
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Re: Super sized injection pump LEAK!!!

Postby 93DodgeCummins » Sat Feb 09, 2013 10:24 pm

Thanks for the info! Ill keep you guys posted
93 Dodge W250 4X4, Custom air intake, Diamond Eye 4 inch turbo back straight pipe exhaust, HX-35W with Banks upgrades, KDP fixed, Getrag 5 speed, Isspro Tach, pyro, fuel pressure, and boost. Raptor 150, 3200 rpm spring, Power Screw in 1 turn, aftermarket fuel pin
93DodgeCummins
fuel screw!!!!
 
Posts: 396
Joined: Thu Dec 03, 2009 6:50 pm
Location: Pickstown, SD
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Re: Super sized injection pump LEAK!!!

Postby 93DodgeCummins » Sun Feb 10, 2013 11:53 am

Got the pump head off. Im betting thats the little 8mm washer you were talking about?

Image
93 Dodge W250 4X4, Custom air intake, Diamond Eye 4 inch turbo back straight pipe exhaust, HX-35W with Banks upgrades, KDP fixed, Getrag 5 speed, Isspro Tach, pyro, fuel pressure, and boost. Raptor 150, 3200 rpm spring, Power Screw in 1 turn, aftermarket fuel pin
93DodgeCummins
fuel screw!!!!
 
Posts: 396
Joined: Thu Dec 03, 2009 6:50 pm
Location: Pickstown, SD
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Re: Super sized injection pump LEAK!!!

Postby Mark Nixon » Sun Feb 10, 2013 4:24 pm

Yes, that's the spacer.
Make sure you're documenting how this came apart, for example the ring that the AFC lever's nub rides in.
It has a chamfer on one edge.
It needs to be re-installed the same way it came out, which is chamfer up, towards the head.

A digital camera is your friend in things like this. :mrgreen:

Mark.
Mark Nixon
 
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