ClassA4x4

Noticed it just today. Diesel dripping at rear of ksb, at the lowest point where there are two threaded empty holes at the bottom if the IP.

What are the most probable places where the diesel is leaking through? It doesnt seem to be coming from the ksb itself nor above it (driver side). And any explanation of the cause of the leak, and of course, repair procedure?

Engine has 175k miles, original IP, runs normal despite of leak.

Thanks in advance.

dodgenstein

There is a cover on the engine side of the KSB piston bore that is retained by 2 bolts. Behind this cover is an o-ring that is known for going bad. You must pull the pump to fix.

ClassA4x4

Are these the allen head bolts that secure the ksb to the IP? Or are the bolts visible only after the ksb is removed?

thrashingcows

Here's a pic of the plate, lower middle of pump....looks like torks head.

jimbo486

Yep, torx-head bolts. Since removal is the only means of repair, you could even consider a reseal of the pump while it's out. 175K isn't a lot of miles but it would last that much longer and then some.

ClassA4x4

Negative. No leak at that plate, not from KSB neither, not from the distribution lines, not from the main fuel screw.

It's hard to see exactly where the leak is coming from, all I can say is it's flowing down from the junction of the black distribution block and the main IP body. Is there an o-oring along that Junction?

What's that bolt whose head looks like a triangle? Could the leak be coming from there?
D

93-12Smoke

Yes, Large ORing At The Head

ClassA4x4

So the black cast block in the picture is called the head? If so, can it be removed from the main IP body without removing the entire pump?

93-12Smoke

It Can Be But Its Difficult. Several ThingS Can Fall Out Of Place.


Sorry ABout My Typing. Dang Android Update Has Messed Up Something With My Text Input And I Can't Figure Out How To Fix it.

thrashingcows

I would not recommend trying to get that o-ring out...I tried it once on a spare pump just to see if I could do it...NOPE!! Once I had the head loose enough to get at the O-ring, the internal springs dropped off the piston head.

I know it's a pain, but pull your pump and do a complete re-seal...DGK-121 is the kit you need. Most diesel shops carry them for about $25.

ClassA4x4

A link to a comprehensive IP re-seal how-to please.

93-12Smoke

https://www.dieseltruckresource.com/...d.php?t=200901

ClassA4x4

Thanks, however that link doesnt go far enough into resealing, or shwing which o-rings are replaced.

thrashingcows

There are enough threads in the sticky to re-seal your pump. A few from Jim Lane about fuel pins, and such. These are all I used to do my first pump....took my time, took tons of pics and measurements, and got it done.

Only problem I had was I did not put a dollop of grease on the thrust washer between the cam and the piston head...so mine fell out of the grove and got jammed up. When it shattered it took out my piston head as well....Doooh!

I had to get another pump, re-sealed that one and was good to go.

Smokin$$away

YouTube has multiple vids on rebuilding so it's basically the same. Pics, notes, and mental notes will get you well on your way! I'm a newby but I have a little mechanical knowledge and with the vids, notes, pics, and a half memory I just did mine!! If you run into problems ask on here and someone will give you info!! Good luck!!