Perkins Perama M20, Volvo MD2020, Perkins 103-06 Injector Pump

[MrCramp]

My spare engine has stood for a bit (in my stable) and I want to start it. It is wired up, got cooling fluid and a diesel supply. When I bleed the diesel through it is going through the lift pump and filter and into the injector pump OK, but none is coming out.

The electric current is going to the valve/switch unit on the end of the injector pump and it does click when I turn the power on. I have jiggled the throttle in and out. There was no problem with the diesel in the lift pump so I don't think there should be any probs with the injector pump being gummed up with old diesel. I have pumped the lift pump and also turned the engine over with the starter a good few tiimes but no diesel will exit the pump into the feed pipes to the injectors.

Does the electric valve/switch just unscrew so I can see if it is moving? I remember that the throttle needed to be moved in and out a bit last time it was running to free the inards up. Can I dismantle it easily?

Gratefull for any ideas, otherwise I will have to get the local Lucas/Bosch injector man out, or try and cart the engine to him.
Paul

 

[DownWest]

I've had the switch out on a couple of Bosch pumps, no prob. Then it was the rubber seal had failed so the engine would not stop. If you hear a click, chances are it is OK. I assume you have undone the injector pipes while cranking. If you remove the solenoid valve, try the lift pump again, just to see it coming out of the hole. After that, Mr Bosch.... Neither of the Bosch pumps I have in road use need to be primed past the feed to the pump. The old CAV DPA pumps needed bleeding in a couple of places.

 

[pappaecho]

You actually do not need a lift pump in this situation. I have a small gravity fed system - an old lawnmower tank with off/ on tap.
The advantage is that virtually no bleeding is neccessary. once connected, if you apply power so the solenoid clicks, and then crank the engine, you should get a spurt of fuel coming out of the injector pump bleed point on the pump. If spurting there you know you have diesel in the pump.
Having done that, you usually can get away with cracking one injector , cranking to get air out of the system. Usually the system starts one one cylinder and then self purges the rest.

Sometimes just a whiff of Easystart helps if the engine has not been run for several years, but dont overdo it

 

[MrCramp]

Thanks for the replies. I am useing the lawnmower tank method and the solenoid valuve is definately clicking. I have now given up for tonight. I took the delivery valves out of the pump. These are where the pipes to the injectors screw onto the pump. The components were moving freely and when they were removed diesel would spurt out of the orifices no problem.

It would appear sufficient pressure is not being generated in the injection pump to open those valves in rotation. When these valves are fitted no diesel comes out the end of them when cranking the engine.

I think I have read somewhere that the govenor can stick, and I think that maybe my problem but I don't know how to get to it. Just hoping that someone who knows these injection pum[ps will come along. I am also going to ask on my Landrover forum as there are loads of grease monkeys there!!

 

[Bilgediver]

Thanks for the replies. I am useing the lawnmower tank method and the solenoid valuve is definately clicking. I have now given up for tonight. I took the delivery valves out of the pump. These are where the pipes to the injectors screw onto the pump. The components were moving freely and when they were removed diesel would spurt out of the orifices no problem.

It would appear sufficient pressure is not being generated in the injection pump to open those valves in rotation. When these valves are fitted no diesel comes out the end of them when cranking the engine.

I think I have read somewhere that the govenor can stick, and I think that maybe my problem but I don't know how to get to it. Just hoping that someone who knows these injection pum[ps will come along. I am also going to ask on my Landrover forum as there are loads of grease monkeys there!!

If you are getting fuel from the pump bores but non when assembled then it sounds like the pump racks and governor are stuck. Usually there is a way of checking this depending on engines. maybe the oil filler or other orifice is near this linkage so allowing access.

It would also appear to be easy to lift the pump off the governor housing
as on page 39 0f the manual. Try not to lose the split pin.

http://www.bluemoment.com/manuals/Volvo_Penta_MD2010-20-30-40.pdf

It may be the pump which is gummed up so easy to free it with a mixture of diesel and engine oil.

 

[MrCramp]

Thanks Bilgediver. I agree it does look easy to lift the pump off. I suppose I should give it a go tomorrow. I am begining to get out of my comfort zone with this, but I feel certain it is just a minor problem and I would like to fix it myself, if I can. I suppose it will be interesting to see what comes out, and what I can see.

I will report back.

 

[Bilgediver]

Thanks Bilgediver. I agree it does look easy to lift the pump off. I suppose I should give it a go tomorrow. I am begining to get out of my comfort zone with this, but I feel certain it is just a minor problem and I would like to fix it myself, if I can. I suppose it will be interesting to see what comes out, and what I can see.

I will report back.

Just make sure you do not lose any shims and they stay in place on the engine as the shim thickness is what maintains the injection timing. Just do not lose the split pin securing to the governor lever.


If the speed connection on the pump is stiff then just spry the mixture of oil and diesel all over the fuel pump body so it seeps in to the rack parts and keep wiggling the speed connection till it is completely free. You might have to spray the governor linkage to which is now exposed.

Once the engine is run yoiu should do an oil change to remove the gunge and diesel.

 

[DaveCass]

I had a similar problem with a Lansing ford, it turned out to be a pressure relief system by-passing the fuel back to inlet.
The cure was to temorarily block the by-pass (this is a pipe which loops around the filter housing) and the eventual cause was old fuel creating a high pressure through the fuel filter thus allowing the relief valve to lift.

Regards

 

[MrCramp]

Well I have got the injection pump (or part thereof) off. The stop lever is stuck in the STOP position which explains why no fuel is going to the injectors. One of the three pumps (no sure that is the right name) is stuck in.

I am taking it to the local Lucas dealer who does my injectors, Eberspacher and anything that I cannot understand. If I was stuck in a desert I would take it to bits but I might as well let the expert look at it as he will explain what he is going to do which will be good.