Zexel Injection pump internal leak repair

   / Zexel Injection pump internal leak repair #1  

Whitbread

Silver Member
Joined
Apr 30, 2018
Messages
162
Tractor
Massey 1740M
Fired up my 1620 the other day and proceeded to blow a 2ft diameter oil puddle out from the crankcase breather tube. I quickly shut it off as soon as I noticed it, pulled the dipstick and it was ALL the way full with the odor of raw diesel. I ran the tractor less than 2 weeks ago and the oil level was perfect so I know it happened sitting since. In order for fuel to gravity drain into the crankcase, there's only a handful of o-rings that can let that happen. Downside is the 9 o-rings are $85 :shocked:. Let's tear in!

After removing the injection lines, you need the pull the two bolts that hold each pumping element in the pump housing. While I'm sure the specialty socket exists, the air hammer with a sharp chisel did the trick to break them free. They are just normal 8mmx1.25 metric bolts easily replaced.


Before pulling the elements out, their EXACT location needs to be marked/measured. The barrels are turned slightly to balance the pump delivery when run on a bench. I used a dremel with a very small burr bit to mark the plate to the pump housing and also measured from the edge of the casting to the edge of each cylinder's plate with calipers to double mark things. A gentle tap with a slide hammer popped the barrels out.


Here's the o-rings that can let fuel seep into the crankcase


All pulled apart and cleaned


Disgustingly overpriced o-rings that were actually in stock at the dealer


All back together


Lube the o rings and GENTLY wiggle the elements back in. Line up your marks and double check measurements.


After lots of cranking to bleed everything out, she's purring like a kitten again!
 
   / Zexel Injection pump internal leak repair #2  
Wow great writeup with nice descriptions and pictures!
 
   / Zexel Injection pump internal leak repair #3  
Real nice work. And the writeup is very professional. I don't intend to be doing any injector pump rebuilds, but it's still a joy to read when anything is done so well.

I'll bet the OP just about choked at the cost of those O rings! I wonder why they are so expensive?

rScotty
 

Tractor & Equipment Auctions

2006 CATERPILLAR 330DL EXCAVATOR (A51246)
2006 CATERPILLAR...
2018 KUBOTA SVL95-2S SKID STEER (A51246)
2018 KUBOTA...
2005 Toyota Tundra Limited Crew Cab Pickup Truck (A51692)
2005 Toyota Tundra...
2010 Ford Edge SE SUV (A51694)
2010 Ford Edge SE...
2023 CATERPILLAR 299D3 SKID STEER (A51246)
2023 CATERPILLAR...
2013 Chevrolet Silverado 1500 Ext. Cab Pickup Truck (A52377)
2013 Chevrolet...
 
Top