3B Lift Pump summary, overhaul, and questions... (1 Viewer)

[izula]

Howdy folks! I have some diesel in my 3B crankcase so I've torn apart a lift pump and replaced a load of internals to get to a little seal that might be the culprit. I have two questions now that it is all back together... But first, some lift pump info from those who have been here before me:

Description of the magic inside a 3B lift pump by @gerg (this in the FAQ section- good stuff!)
Lift pump video by @duncanrm
Duncanrm's 2H lift pump failure post

I'm going to post a bunch of photos, some part numbers, and try to document everything needed to fix one of these pumps...

1. The tappet that follows the Injection Pump cam has an oil passage in it. I did not notice whether the tappet is oriented with the hole 'up' or 'down'. Anyone know?

2. The seal for the shaft which the tappet pushes on to actuate the lift pump came out with the shaft. This is the seal that I suspect is leaking on my lift pump (I tore open and replaced parts on a donor lift pump...). Is this seal supposed to be pressed in to the lift pump body or does the tappet follower slam it into place? Photos to follow will help to understand.

Thanks!

 

[izula]

Here's a photo of the tappet with the hole:

 

[izula]

Exploded photo of the tappet:

 

[izula]

Tappet, seal, and shaft:

 

[izula]

And here's an old image from @lostmarbles that shows the pump's internals. Note that the primer pump in this image is on the left side of the lift pump. On my lift pump, the primer pump is on the right side (as well as the filter). The passages in the left side and right side of my pump body are different, so this might be something to be aware of if you are looking for exact comparison... however, the guts should be the same.

Also, note that the seal I'm focused on is not in the image.

 

[izula]

Here are some images of the seal. I purchased a replacement seal from Keva Diesel using a part number (949150-2700) from another mud post (I'll dig it up and link to it with an edit later). I'm not sure it is a correct replacement. I ended up using the original one. Since this is a donor pump and not the one that I suspect is leaking, I'm okay with that for now. Unless I damaged the seal by pressing it into place (question #2)...

 

[izula]

Here's the side of the pump that mounts to the Injection Pump. Note that the image is almost upside-down...

The red arrow points to the area where the oil seal makes contact with the pump body. It is raised from the base of the cavity so that is why I pressed the oil seal down somewhat (10mm deep socket with a watch hammer while the shaft was in place).

The blue arrow points to a pile of sludge (on the oil side of the pump) which is a result of what I believe to be the tappet oil passage location. I think it was orientated as 'down'.

 

[izula]

Now for some part numbers...

Denso Overhaul Gasket Kit for a feed pump (Denso #192290-0060). I found this on ebay for $30 or something. It comes with the check valves, copper washers (Mr. T has them as well, but they are a bit spendy for a copper washer), a fancy priming pump cover, and a snap ring. The is not the exact kit needed for the Denso lift pump 092100-1101 (the pump on my 3B). But the copper washers, snap ring, and check valves seem to be a universal fit for these Denso lift pumps. Some Denso part numbers for these parts are included in the schematic from the kit shown below.

Toyota O-ring to seal the Lift Pump to the Injection Pump (IP) (90099-14015, Ring, O). I think these are still available from Toyota. This is not reusable per the factory service manual (FSM). You could probably reuse it in a pinch if you don't destroy it when you remove the lift pump from the IP.

 

[izula]

I sourced the springs for the check valves from Lift Parts Warehouse (KODK152116-0200 DK152116-0200 : Spring For Komatsu & Allis-chalmers, $7 ). These springs appear to be the same for Mercedes lift pumps and Bosch lift pumps as well. There are probably better sources for these springs (2 needed for each lift pump). Mercedessource.com has a kit with check valves, springs, a few nuts and a non-applicable gasket for only $32. It comes with a how-to video as well. I might pick one up just to check out the comparability...

 

[izula]

Toyota Filter (22529-67010, Filter): Inside the banjo bolt on the right side of the lift pump (input from fuel tank) is a little filter screen that can get clogged if you run snotty fuel for 30 years or veggie oil. Toyota still sells them and they're cheap. These have been discussed before on Mud.

Toyota Spring Washer (94511-00600, Washer, Spring): Also, if you manage to lose one of the spring washers on the three mounting bolts to the IP (like me...), Toyota will sell you new ones.

 

[izula]

Lastly, some more photos from the kitchen table:

 

[izula]

And a few more:

 

[izula]

Yup...

 

[izula]

Last three:

 

[Nz Nath]

I have a spare 13bt lift pump here which should be identical. The hole in the tappet is at the top.

 

[izula]

Ahhh! Yes, it should be identical. I have not torqued the plunger and spring down yet, so flipping it is relatively easy. I still have the lift pump that is on my rig too. When I swap the leaky one with the refurbished one, I'll note what the orientation is. Well, after I get some insight into question #2. Thanks @Nz Nath!

 

[izula]

Some more info:

A post by @robstar from 2017 (post #21 from this thread) stated:
"FYI there is an internal oil seal for the 22510-56040 PUMP ASSY, FUEL FEED
body.
The Denso part number is 949150-0970 or 90099-15026."

My local Diesel Forward (used to be Central Motive Power) has them for $2 and change. I've got three lift pumps, so I ordered three seals. I'll post up what they look like on Thursday or so. Now all we need is a proper replacement procedure and we're golden! I'll ask the guys at Diesel Forward when I pick up the seals. They used to be really helpful, so I'll see if that is the same situation now.

Also, a little websearch yielded this gem:

 

[duncanrm]

Superb information, photos and narrative.. thanks!

 

[izula]

UPDATE:

I spent some quality time with a technician at Diesel Forward (DF) here in Albuquerque and determined the correct parts and procedure to overhaul a Denso feed/lift pump for the inline injection pumps on many of our rigs. The rotary IPs have an internal lift pump, so this information does not apply to those. Also, many of the feed/lift pumps have the same internal parts, although the body may have different passegs/plumbing. The details I have are for the Denso 092100-1101 feed/lift pump, but would most likely cross reference to another Denso pump. The oil seal is specific to the Denso pump. The remainder could probably work on a mercedes pumps or any other pump that looks similar.

The correct Overhaul Gasket Kit is Denso 192290-0060 (I posted photos in an earlier post). The kit is lacking the oil seal and two springs... DF sells them for around $16 and change.
The correct Oil Seal is Denso 949150-0970. DF sells these for $2.29 each.
The correct check valve Spring is Denso 092124-0010. You'll need two of them. DF sells them for $0.67 each.

So the bottom line is you can overhaul a pump for about $20 using OEM Denso parts. There are kits on Ebay and the like for less, but no oil seal and who knows where the parts are coming from. I'm happy spending $20 for known quality (350,000 kms on my pump).

Also, the Mercedes folks claim that the check valve springs go soft over time and can cause poor feed flows/pressure. So for $1.50 you can remedy that potential issue.

Last but not least- the correct procedure to install the oil seal is to lightly press the seal into the cylinder until it seats on the bottom of the cylinder. Use a socket, press, whatever- just don't damage the seal surface. Picking out the old one could use some ingenuity, but its not brain surgery. I'm going to replace the old seal on the pump I just serviced and document the process. Also, I'm going to call the technician back tomorrow and ask about the oil passage orientation (I forgot to ask today). When I get all the details sorted I'll update the first post with part numbers and answers to my questions for posterity. The good folks at DF said they would be happy to take your money for parts if you prefer to deal with real people rather than a website. Good luck

 

[BajaTank]

Great info and thank you for the part numbers.
I found a new complete OEM pump at https://www.carpartsdirect.asia/
If you have a daily driver like me and cannot wait until you have time to rebuild your old one. $181 bucks