I have been going round and round with this one but I think I am getting close. After re-reading many posts, I decided while the engine was running, starting at the number 6 cylinder, to break the seal on each injection line. Breaking the seal on injectors 6, 5, 4, 1, increased engine roughness. When I open the seal on the #3 injector, there was no change in engine roughness. I also opened the seal at the injection pump which also did not created engine roughness. A number of months ago, I got a special socket and removed the lines from the injector pump. The question is, can 1 port fail on the injection pump or is it possible that I assembled something incorrectly when I resealed the lines into the injection pump? Hopefully this makes sense.

Any fuel leaks at the IP after you diddled with the lines there?

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Cheers!
Scott McPhee

1987 300D

If the Delivery Valve Seal is not leaking:

The Injector Cut out Test does not necessarily mean that is a Fuel Injection Problem.

It identifies an issue from the Fuel Injection Pump on into the Cylinder.

Swapping the #3 Injector to another Cylinder and see if the Problem follows the Injector. If so you have an Injector problem.
If you sell have a prblem ager swapping the position of the Injector the Cylinder or the Fuel Injection Pump are the problem.

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84 300D, 82 Volvo 244Gl Diesel

Some how I feel that the number 2 injector is not getting enough pressure from the injector pump to make it pop. I have not swapped injectors yet but I will after this post. I did remove and inspected the number 2 and 3 caps off the injector pump and everything looks in order. It seems to me that an injector pump either works or does not work.

I swapped the injector 1 and 2. There is some fuel coming out of the line when I creak the line at the injector but the pressure does not seem to be as high as the others. Is there any thing I can check at the pump? The stack up was the same on both 2 and 3 delivery valves. I have not tried to take the side cover off.

Now I am not getting any fuel to the injectors??

I usually at pretty good D.I.Y. guy but this injection pump issue might be over the top for me. Does any nobody know a good shop up this way? Plattsburgh NY. 1.5 hr south of Montreal and across the lake from Burlington VT.

OK I might have up but hopefully not too much. I used a magnet and extracted the assembly. What is the proper orientation of the holes and the slot on the bottom? I put the parts back in with think about orientation and engine will not start.

I am answering this from a PM I recieved.

The Delivery Valve is 2 parts and the marts are mated together and only mated together on one end of the Delivery Valve. So if the parts were swapped between different Delivery Valves they will not seal right and if you put the central Valve into the wrong end of the Cylinder it will not seal right.
However, I don't think getting those out of order would cause a no start. It might case erratic Idle or higer speeds.

The Delivery Valve does not have a Slot in it. It does have more tha one or more bands machined around the Body of the Cylinder that is supposed to help you get the central Valve back into the Correct end of the Cylinder. I have had your Year and Model IP apart so I don't know if where the band is on yours.

If the Slot you are speaking of is on the Part below the Delivery Valve, that is the Barrel of the element.

That slot lines up with a Locating Pin inside of the housing Bore. If that Barrel is installed with the Pin not in the slot it can damage the Fuel Injection pump Housing. But, more often it simply pushes the Pin out of the way.
If you remove the Cover that is behind the Fuel Supply/Lift Pump you will see the Rack and Tappet Srings and at the very top where the Cover Gasket would cover you will see a line of Steel Pins that are staked over to keep them from moving out.

If the Element Barrel was installed wrong and the Pin was pushed out it you shoild be able to see that by comparing it to the Position of the other pins.

I will find some pics to Post

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84 300D, 82 Volvo 244Gl Diesel

In the pic with the Delivery Valve Body the later models may have more than one ring around the body.

Attached Thumbnails

       

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84 300D, 82 Volvo 244Gl Diesel