Injection pump leak

[Sen Mora]

Hi, I have B41 2003 with D2-55A engine. Recently I have noticed a small leak on the injection pump under the flanges holding the delivery tubes to 2nd and 3rd injectors. The nuts (or screws) are 5 sided so no regular tool can be used to try tightening. As additional note I have noticed that when the engine starts a dripping can be observed after several minutes engine gets hot and the leak changes to a fine sweating. I wander if anyone had experience with similar issue. Many thanks for comments / suggestion (other than removing the pump, we live aboard during the winter months).

[Yngmar]

I don't know why your injector pump is leaking or what those 5-sided bolts actually do, but I can tell you they're called Penta, Pentahead or (in Europe) Pentagon head bolts and sockets for them are available on eBay for various sizes.

You should find out what the bolts are for before tightening them though - there usually is a reason for using special ones, and often the reason is because you're not supposed to fiddle with them - they might be adjustment ones

[Sen Mora]

Thanks for the coment, it looks to me the penta nuts hold down the flanges, the leaks are under them. I can actually see a fine bubbling when engine is running. I have the shop manual and spare parts lists, neither of them shows that detail. I would definitely like to see how it is put together before trying anything. I have difficulty to find who made this pump and a diagram showing the details. Any help on this?

[JEN-et-ROSS]

http://www.denso.com.sg/images/products/nb_ep9m.jpg
 
Have a look at the above jpg,
it seems that these bolts are simply holding each injector cylinder flange in place.
 I'd probably have a go at carefully tightening them, but with all things 'injector pump' and the fact that, as someone else pointed out, they have used odd shaped bolts, be careful if you do.

[Sen Mora]

Many thanks for a good picture. I just wonder if there are some o-rings between the flange and the pump body. I would still like to find the make of the pump and a place with spares for it, they should have a part list/catalog as there are quite a number of parts in the pump. Volvo penta does not go into details on this. I have ordered a pentagon socket, it'll take some 2 weeks to get fro GB to Virgin islands so in the meantime will live with the small leak, hoping it won't get much worse.

[Yngmar]

Did you already try tightening the fuel pipe compression nuts? It may just be that and the fuel is only coming out somewhere that makes it look like it's those Pentahead bolts.

[tiger79]

I would still like to find the make of the pump and a place with spares for it, they should have a part list/catalog as there are quite a number of parts in the pump.

The link given to the pump drawing was from a Denso website, so it's probably a Denso pump, although I've also seen it described as a Zexel.  The D2-55 is based on a Perkins 400-series engine, I believe, so that may help you in locating parts information.  Injection pumps are incredibly fiddly things and frankly are best given to specialists to repair.  In your case, with only a slight leak, you can probably get the bolted-on flange off yourself and have a look.  If you look at the Volvo parts diagrams, you'll see that there's a spring-loaded valve screwed in to the flange, so be ready to catch the bits!

[Sen Mora]

Thanks for the last replies, for one the fuel line area is perfectly dry and when engine runs there is a fine bubbling action right between the two flanges on the pump body.
Thanks for reference to Perkins, have not yet found the exact model, hopefully the tightening will be enough so the removal of the flange won't be necessary'

[Ronald]

https://www.marinepartseurope.com/de/volvo-penta-explosionsdarstellung-7744440-23-5492.aspx

Is this of Any help?

Regards Ronald.

[Sen Mora]

I have the same, it does not show details of the pump, only what is attached to it. Thanks anyway Ronald.

[Ronald]

Hello Sen Mora

I do have the workshop manual of the D2 and that shows that the bolds are merely holding the top half of the Pump.
AT least when I understand correctly which bolt you are referring to.

I you send me a PM with your E mail I am happy to mail you the manual, which can be helpfull but does not show the inside of the fuel pump.

Regards Ronald

[Sen Mora]

Thank you Ronald, but I also have the workshop manual.