Re-sealing your leaking in-line Zexel aka Boschn PFR diesel injection pump

[jacobmindler]

Personal, I think I would remove it from the engine.
Under the pump is a camshaft and roller.. if the cam is on the hi point of it’s stroke, pushing up on the roller.. it’s very possible that once u loosen the top nut, the internals will get pushed up also..& u don’t want that to happen.!!
The barrel assembly is located in a very specific spot by a lead pin.. if the barrel gets pushed up, off that pin, it’s got 1 chance to fall back onto that pin.. otherwise, when u TORQUE the top nut back down, you’ll shear off the pin..THEN IT WONT WORK CORRECTLY..
& if you take it to a fuel shop, they’ll tell you u hafta buy another complete pump.

If I remove it I just undo those 4 bolts and pull it straight out? Or is there something I have to remove under it? Thanks for the reply

 

[jacobmindler]

Personal, I think I would remove it from the engine.
Under the pump is a camshaft and roller.. if the cam is on the hi point of it’s stroke, pushing up on the roller.. it’s very possible that once u loosen the top nut, the internals will get pushed up also..& u don’t want that to happen.!!
The barrel assembly is located in a very specific spot by a lead pin.. if the barrel gets pushed up, off that pin, it’s got 1 chance to fall back onto that pin.. otherwise, when u TORQUE the top nut back down, you’ll shear off the pin..THEN IT WONT WORK CORRECTLY..
& if you take it to a fuel shop, they’ll tell you u hafta buy another complete pump.

Also what about removing the 2 bolts and pulling it intact with the barrel and nut replace the 2 orings and while it's out take the nut off to do that final oring would that be ok?

 

[jacobmindler]

Thanks to both of you for the advice

 

[jacobmindler]

Turn out well did 2 injectors no more leak

 

[jacobmindler]

Pumps

 

[Redz]

Great, I was worried about you doing it on the machine , outside in the weather, if something drops etc. There are a bunch of videos on YouTube and almost everyone takes the whole pump out and works inside on the clean, flat work surface. Glad you were successful.

 

[Redz]

For reference here is another company that sells a lot of parts for the many varieties of these bosch Zexel PFR pumps. Unfortunately this company is in UK but if you can get around that, heck they even sell those darn 5 sided bolts:

Injectionpumps UK

Bosch / Denso / Zexel PF / PFR Pumps Archives - Page 2 of 8 - Diesel Injection Pumps

Bosch PF type flange mounted plunger pumps are fitted to many small commercial diesels and made under licence by manufacturers such as Lombardini, Ruggerini, Zexel, Kiki and Denso. Commonly used in engines and equipment made by Mitsubishi, Nissan, Yanmar, IHI, Shibaura, Kubota and Honda

injectionpumps.co.uk

 

[thepumpguysc]

ANY inj pump shop will fill that order

 

[jonsstihl]

thank you to everyone here that provided info. It is nice to have both sides of the story. one guy who was willing to try and be successful and the other guy warning others about the dangers of all the little details.

it just means there is more info for the reader to decide if he wants to tackle the repair himself or send it out.

 

[m2mexpert]

Those 5 sided screws are there for a reason.. just sayin'..
Did u know THAT TOOL is OVER 300.00.!!! & that's an aftermarket tool.!!
It probably wouldnt hold up to the pounding u have to do using a hand impact driver.?? It would prob. strip-out..
I have the OEM Zexel tool..
There are many variations to that pump & u only encountered 1 type..
I get them in ALL the time with "sawed-off" screws where a fix was attempted..
& to be perfectly honest, it usually results in the customer buying a new pump..
.. just because the parts are so expensive to FIX a failed attempt.
That P# u listed is only for 1 type of Zexel pump..
I commend your "luck" but posting a "how to" thread just because u got lucky.??
I know its been done before w/ decent results but as a side note,
...u should warn any potential "armchair mechanic" that catastrophic results MAY occur..

I have this same pump (or very close to it). It works fine but leaks around the top of one flange. It is probably as simple as replacing the O rings… .what do you charge to replace the O rings? I’m not afraid of giving it a try but if the cost is not unreasonably high, I would send it to you.