Volvo Penta MD2020B fuel injection pump leak

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Iseo395

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Hi All,
New to the forum but not to boats! I have a 40’ catamaran built in 1998 with the original VP MD2020B 19hp engines. Apart from the odd drip here and there they run flawlessly, but one of the fuel injection pumps has developed a significant leak recently. The fuel pump Part # for this engine appears to be 3580263 (picture attached) and the leak appears to be coming from where Part #3 screws into the pump body.

My question is two fold:
Is it a simple enough task to rebuild this part of the pump with new O rings/washers to solve the issue, and if so which part numbers are required for the job?
Should I decide to replace the entire injection pump rather than rebuild, is it a simple plug and play operation or does the new pump need to be set up timing wise to match the existing engine?

My boat is currently in the Bahamas whilst I am home for the Summer so I am hoping to purchase the relevant parts here in the UK so they can be fitted by the boat yard mechanics when I return!

Thanks all!
 
Iseo395 said:
Hi All,
New to the forum but not to boats! I have a 40’ catamaran built in 1998 with the original VP MD2020B 19hp engines. Apart from the odd drip here and there they run flawlessly, but one of the fuel injection pumps has developed a significant leak recently. The fuel pump Part # for this engine appears to be 3580263 (picture attached) and the leak appears to be coming from where Part #3 screws into the pump body.
My question is two fold:
Is it a simple enough task to rebuild this part of the pump with new O rings/washers to solve the issue, and if so which part numbers are required for the job?
Should I decide to replace the entire injection pump rather than rebuild, is it a simple plug and play operation or does the new pump need to be set up timing wise to match the existing engine?
My boat is currently in the Bahamas whilst I am home for the Summer so I am hoping to purchase the relevant parts here in the UK so they can be fitted by the boat yard mechanics when I return!
Thanks all!
Click to expand...
No picture probably because you are a new member.
However link to the relevant page in the parts catalogue here

Are you absolutely sure the leak is from between #3 and the pump body and not from the delivery pipe union
If where you suggest probably only the O ring that needs to be replaced.

See this warning about refitting the pressure valve holder ( #3) in the workshop manual

WARNING! The pressure valve holder must be screwed in by hand so that it is possible to feel that the pressure valve goes correctly into the valve holder. Never use force to screw the valve holder down since this can damage the pressure valve. If the pressure valve cannot be turned in the valve holder the pump must be dismantled and the same method applied with the pump in a completely horizontal position.​
​
(Final tightening torque is 35-39 Nm)

Workshop manual here
or
 
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VicS said:
No picture probably because you are a new member.
However link to the relevant page in the parts catalogue here

Are you absolutely sure the leak is from between #3 and the pump body and not from the delivery pipe union
If where you suggest probably only the O ring that needs to be replaced.

See this warning about refitting the pressure valve holder ( #3) in the workshop manual

WARNING! The pressure valve holder must be screwed in by hand so that it is possible to feel that the pressure valve goes correctly into the valve holder. Never use force to screw the valve holder down since this can damage the pressure valve. If the pressure valve cannot be turned in the valve holder the pump must be dismantled and the same method applied with the pump in a completely horizontal position.​
​
(Final tightening torque is 35-39 Nm)

Workshop manual here
or
Click to expand...
 
Hi Vic, many thanks for your reply - in answer, no I am not 100% certain the leak is from #3, but this was the boatyard mechanic’s opinion when he looked at it (we are talking the Islands however so how qualified he is is questionable)
I assume by the ‘delivery pipe union’ you are talking parts #18,19,20? I am no where near knowledgeable about engines to attempt this myself so it will have to be done by the yard guys - my options are to rebuild the existing pump or simply buy a new pump.
If rebuilding is a sensible option I am trying to establish which parts i need and if I go with a full new pump, I’m wondering if it is just a straight plug and play replacement of if the new unit will need the timing set to match the existing engine (as I said, my knowledge is extremely limited so excuse me if I’m not making sense here!)

Thanks again for taking the time to answer!
 
Iseo395 said:
Hi Vic, many thanks for your reply - in answer, no I am not 100% certain the leak is from #3, but this was the boatyard mechanic’s opinion when he looked at it (we are talking the Islands however so how qualified he is is questionable)
I assume by the ‘delivery pipe union’ you are talking parts #18,19,20? I am no where near knowledgeable about engines to attempt this myself so it will have to be done by the yard guys - my options are to rebuild the existing pump or simply buy a new pump.
If rebuilding is a sensible option I am trying to establish which parts i need and if I go with a full new pump, I’m wondering if it is just a straight plug and play replacement of if the new unit will need the timing set to match the existing engine (as I said, my knowledge is extremely limited so excuse me if I’m not making sense here!)

Thanks again for taking the time to answer!
Click to expand...

No , The pipe(s) from the pump to the injector(s) # 26, 27 and 28 on the full fuel system diagram.

With luck all that will need replacing is the O ring. If the whole pump has the be removed to refit the pressure valve holder it'll be a fair bit of work but at least it should drop back in using the original shims without needing any adjustment

If you replace the whole injection pump (VP's price for a new pump is €1,880 ) the shimming will have to be checked and adjusted . See the WS manual.

I would want to be very certain that its not just the delivery pipe union that is leaking before touching the pump.
 
If its not the delivery pipe and the pump itself is leaking a diesel fuel injection specialist (non marine) will be able to strip it down, replace all the seals and test it so it's like new for around £200, or at least thats what it cost me in the UK to have the pump on my MD2040 sorted. Mine was a Zexel pump that's fitted to numerous other engines so there's no need for VP parts and I imagine yours will also be a generic pump. Only one of the internal seals was leaking but the rest were all about to go the same way which was just an age thing as they had gone hard / square. This is way cheaper and easier to fit than a new pump but make sure you read the manual carefully when removing and reftting the pump and don't damage the existing shims as you'll need these as VicS has said.
 
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Ammonite said:
If its not the delivery pipe and the pump itself is leaking a diesel fuel injection specialist (non marine) will be able to strip it down, replace all the seals and test it so it's like new for around £200, or at least thats what it cost me in the UK to have the pump on my MD2040 sorted. Mine was a Zexel pump that's fitted to numerous other engines so there's no need for VP parts and I imagine yours will also be a generic pump. Only one of the internal seals was leaking but the rest were all about to go the same way which was just an age thing as they had gone hard / square. This is way cheaper and easier to fit than a new pump but make sure you read the manual carefully when removing and reftting the pump and don't damage the existing shims as you'll need these as VicS has said.
Click to expand...

Thanks for the reply and I had considered removing the pump and carrying it home to be rebuilt here in the UK - can you recommend whoever did the job for you?
Thanks
 
Iseo395 said:
Thanks for the reply and I had considered removing the pump and carrying it home to be rebuilt here in the UK - can you recommend whoever did the job for you?
Thanks
Click to expand...
I used these guys. Turn around time was a few days and it cost £165 + VAT. I haven't used them for anything else but would happily use them again based on this experience.
S&S
 
I would suggest that following the service you obtain a couple of those O rings as spare as there has been a spate of pumps leaking at that location recently . It is a fiddly job changing them but might get you home.
 
Bilgediver said:
I would suggest that following the service you obtain a couple of those O rings as spare as there has been a spate of pumps leaking at that location recently . It is a fiddly job changing them but might get you home.
Click to expand...

I assume you are talking about the O ring part #4?
Thanks!
 
If you get the pump rebuilt and all the seals changed I suspect it will be another 20+ years until it leaks again by which time you will have gone electric..or lost the spare o rings :cool:
I did ask S&S whether it was the changes in the fuel that were causing the problems and while potentially a factor I was told it was more of an age thing.
 
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