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ASV RC-100 Delphi Fuel Injection Pump

H

HuDee

New User
Delphi Fuel Injection Pump 9320A192G

Skidsteer sitting for 4 years. Now no fuel to injectors (observed with lines disconnected at injectors) when starting. Replaced fuel filters. Bled air from system. Replaced shutdown solenoid with no improvement. Can hear solenoid energize when connector removed and installed. Observe very, very small fuel flow from injection pump return port with hose disconnected and fuel transfer pump running.

1. What can be preventing fuel flow to injectors?
2. How can pump rotation be verified without major disassembly?
3. Should more fuel be expected from injection pump return port?

Any diagnostic ideas would be appreciated.
 

So youre saying the electric fuel pump in the filter housing is running, if so Id first check the water separator located on the right side of the engine compartment near the hydraulic filters
It looks like a CAV filter but should be a washable screen unless someone has mistaken it for a filter and replaced it
With the key on I can hear fuel returning back to the fuel tank when I have the cab off
Theres also a fuse in the box that powers the pumps shutdown solenoid
 
Fuse to shutdown solenoid confirmed good. Voltage to solenoid at connector good. Can hear solenoid energize when connector is installed.
Replaced shutdown solenoid with new and still no fuel to injectors when engine is cranked.

Fuel-water separator replaced. Fuel flowing from transfer pump back to tank through return confirmed OK.

By the way, the injection pump is a DP-210. Failed to specify that earlier.

Is is possible the throttle cable operates the lever on top of the injection pump without actually moving the pump internals to allow fuel flow? I don't know too much about this pump. Information is difficult to locate.

Prior to starting the engine after 4 years, I rotated the fan by hand to check for fluid in the cylinders before attempting to start. Realized later I turned then engine opposite of its normal rotation. Can't imagine that would damage the injection pump, but I mention this in case someone knows more about this than me, which would be pretty easy.

Thanks.
 
The injection pump won't be hurt by turning engine backward. The DP 200/210 pumps still have a metering valve and rotor plungers that can stick from setting unused awhile with old stale fuel just like the older DPA and DPS pumps have. You will need a service manual for the correct timing procedure, as pump/engine is probably lock timed.
My guess is injection pump probably needs to come off for a complete tear down and cleaning before it will work again.
 
put a 5 gal. can of fuel on the roof of the cab & run a fuel line direct after you've siphon-filled the line. Should run.
 
Would injector cleaner or other solvent be helpful in releasing the sticking parts vs. tear down?
 
I would really like to avoid tear down. I was considering vibrating the pump housing to see if I could get things to loosen up in there, but its sounds like the parts could be seized pretty tight if a punch is needed.

If I lock the engine properly and lock the pump shaft properly, is there any chance of partial disassembly and cleaning that would not also require factory setup of the pump before reinstallation? Trying to stay on a poor man's budget.
 
Having been repairing/testing pumps over forty-five years and counting, I know there's NO shortcuts to repair the Delphi DP200/210 series pumps. They are the most expensive, time consuming pump Delphi has. At my age I'm GLAD I don't have the testing equipment for them, there's enough older pumps I do have equipment for to keep me busy..
 
Diseltech is telling you right you are up a creek with out the paddle as the guy says pump has to go to the shop and get ready for a nice deep bill.
 

Im just wondering why the machine set for 4 years
I have a RC85 with the non turbo version of that engine, rarely does it set for more than 6 months without use
I have ran it out of fuel a few times and can say its been near impossible to bleed out and restart without using starting fluid
 
There's no easy way on that pump to see if the rotor is turning. If it does not deliver fuel to injectors after checking the solenoid and fuel supply, pump needs to come
off for repair.
 
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