Kubota 3 cylinder diesel Zexel injection pump rebuild Part 1

I purchased a former Air Force FL-1D model light plant (basically a flight line version of a highway construction light plant), that had a 3 cylinder Kubota diesel in it. The injection pump was locked up, and would not allow fuel to flow to the injectors.
Follow along with me as I disassemble and figure out what the problem is, and fix it!

[@jimt902]

Thanks, you helped me get my problem figured out. On mine, parts 19 and 20 in that diagram you showed, were bent slightly. Just enough to hang up every once and a while. I hammered them flat and cleaned everything and she's back up and running.

[@mclark3119]

Thank you! I was able to get my L245DT running again after watching this video. Subscribed

[@nobbienz]

Fantastic video, just about solved my problem! Thanks for taking the time to film this

[@herewegofans]

Thank you for your service and video. Helped me find my injector challenge on a engine.

[@_P0tat07_]

Thanks for the video man! We can’t get our fairway mower to start at work. Really hoping this will help us. I would assume it would cause the shut off slide is really stiff on ours. I’m not even the mechanic, I’ve just taken fascination with working on equipment 😄 Update: one injector was bad. Pulled it apart and it looked really clean, but the plunger was really stiff. Not a spec of rust and no visible burrs. The parts manual for the engine included all the part numbers, but the parts weren’t labeled. Tried ordering parts from the dealer. Dealer said we can only buy the entire pump assembly. At a cost of over $1000. Not sure what we’re going to do yet.

[@jorgegar5055]

I am doing mine as I write, and the middle piston had a washer but the other two did not, so what he was worried about is normal, I know mine has never been apart

[@davidnavarro3410]

Great video I am working on my tractor same problem it sit for to long !!!!

[@khriswalenga6934]

Where did you find rebuild kit

[@MrTubeman007]

You don't strip these down like that at all, you certainly don't remove the torque screws from the top. Undo the 17 mm diesel nuts from the top and the spring unit you were fighting with at the bottom will just drop out.

[@cornbread10378]

Awesome video man..

[@michaelvadney5803]

Question for you. If you just have a set of bad o-rings could you get away with just pulling the two security-torx and remove the upper portion?

[@peterrocco2024]

I tell my employees that if they use KZbin for learning to make sure they watch videos that are from people that know what they are talking about. If you put one of these pimps together wrong you will go wide open throttle and say y by engine.

[@KOSTAS2231]

Hi , when remove the pump from engine did you check timing? Or just remove botls? I am sure after rebuilt pump and put again in engine you need to check timing ? Best regards Very helpful video!

[@steamman5320]

No need, while this is a distribution style pump (the fuel is pressurized and delivered at the proper time to the injectors by the injection pump, unlike a common rail system where the IP simply pressurizes the fuel, and the cam shaft or electric pulse fires the injectors) the timing is controlled by a small three lobe camshaft inside the lower part of the injector/govenor housing. The rollers on the pump ride on the shaft to provide the timing. Since I didn't have to take that shaft out, there is no need to check the timing. Simply disconnect the govenor/throttle linkages, remove shut off solenoid and fuel lines, unbolt and remove. Very simple system.

[@KOSTAS2231]

@@steamman5320 many thanks again! Congratulations! You are a skilled man!

[@flightace1]

Do u remember if the 2 O-rings on the body whas the same? i rebuilding one myself and the upper grove is 16,9mm and the lower one 15,9 but the seals in the kit is the same size so i don´t dare to order that kit,

[@steamman5320]

I believe they were the same size o rings, at least I didn't match them anywhere and it has been running fine for years that way. O rings can stretch a little no problem. One mm is nothing really.

[@michaelbirchall2247]

I hear a lot of people saying that the top "turret" (where the fuel lines are connected) is tuned by the amount that it is screwed in or out, and if you move it then you need to send it off to get re-tuned. But this appears to be false?

[@steamman5320]

I believe that rotating them as you said can change the timing of the fuel, however I set them back right were they had been (could tell by the paint removed) and it starts, runs, and loads fine.

[@danielboyd9507]

Where did you find this manual

[@shalensharma636]

Great video, can the fuel leak from this down the crankcase and mix with oil and if so what causes it and how to repair it, cheers

[@joemersonlago3053]

Bom dia! Assisto seus vídeos . Sou do Brasil e gostaria de saber se poderia me enviar uma foto dessa página do seu manual

[@rosemariesangil245]

Fantastic video just a question, can you remove the injector pump without touching the Gove or/throttle linkage? I have a Kubota D1005-E engine. I would have loved to see you remove it

[@cpaul1093]

Hello thanks for sharing! Where does one find a repair kit with O-rings??? Thanks!!

[@gottistyle623]

Where did you order new o-rings

[@danjimielson]

Yea I need new o rings too for a different Kubota fuel pump

[@DevinGraham-mt5vw]

Do you have anything on the linkage to that pump?

[@witcher71]

I wonder if it was "Carb Dipped" if it would have cleaned up without disassembly?

[@steamman5320]

Possibly, if the cleaning agent would be able to get into the pump with it locked the way it was. I tore it down more because I had know idea what was wrong, could have been something bent or broken, or really rusted solid. If someone has one with the same issue, it would be worth a try I suppose.

[@aruntikore339]

Hi ,,how to increse fuel from fuel pump any setting....

[@iwantosavemoney]

They call them money trees

[@StephenBrewer89]

Can you pull that pump straight off? Or do I need to take anything off the drive assembly off? Curious mainly about lining up the shut off shaft.

[@steamman5320]

Yes, no need to remove the cam below it. Pump comes right out, after linkages are disconnected.

[@StephenBrewer89]

@@steamman5320 awesome! So I can just remove my linkage, and the 4 bolts holding it in, and lift it out? What about the spring that pushes on shut off shaft

[@steamman5320]

@@StephenBrewer89 if I remember correctly, you take the plate off the front, unhook the spring with shutoff linkage, and the four top bolts and it just lifts out.

[@StephenBrewer89]

@@steamman5320 thank you! Big help

[@michaelvadney5803]

Thanks for making that man. Question: where do you find new o-rings?

[@_P0tat07_]

Call your local kubota dealer. They should be able to get all replacement parts for you.

[@michaelvadney5803]

I did a full rebuild and used factory o-rings. No more leaks. Seeing videos like your takes the black magic out of the equation, thanks.

[@howardhaberern5686]

Where can I get a parts listing or repair manual for my 15841-51010 Zexel injection pump

[@sammydog1959]

Is it raining? nice vid

[@nobbienz]

I do have a question, Was replacing my glow plugs and needed to remove my fuel lines to access, I ended up taking out the fuel injector piston/spring assembly but the main body with two o rings was still inside. When removing the piston a flake of paint fell into the injector pump, I’m at a loss how to get the paint flake out. The engines on a boat so not great access for full removal, any ideas would be hugely appreciated. I did attempt to start the engine before identifying that the paint flake inside was probably a bad thing :-( Also, if I was to remove the pump, do I need to mess with attaching/detaching the governor spring?

[@taylorbrian89utube]

Well a little late to the party here, but since the engine ran a bit can you tell if there is only one cylinder that's not firing? It's possible that the plaint flake got jammed into an injector nozzle. If thats the case then maby an injector nozzle needs to be replaced. Hard to say if there is any other damage. Id have the injectors pop and flow tested at a injection shop and go from there.

[@buddyboy1953]

I also have a D905 diesel engine. When she runs for a minute it revs up without touching the throttle. I change the exact pump you tore apart. Any ideas on what would cause that ? thanks,Ken

[@steamman5320]

Was it doing it before you changed the pump? Maybe the spring for the governor, or the governor itself is messed up or broken?

[@sumanmondalsuman7635]

Thanks you very much Recoste Sir engine repair manual clashon address please sir

[@otisjames5175]

Kaboota, haha

[@soup2nuts1957]

Spray wd40 works wonders

[@peterrocco2024]

WOW, if you don’t know what you’re doing or talking about you shouldn’t make a video. You have no idea how the pump works but are telling others how it does. A lot of guessing and 90% of your guesses are wrong. You can do some serious damage to the pump and engine not doing one right.

[@beaurampey375]

I agree. might be smart and lucky enough to take apart and put back together and it work. But teaching is a whole diffrent ball game. Guys if u watch this video mute the sound and u will be fine

[@josephmcbeth4988]

I watch the whole video and all you did was tell me how to take it apart that is not a rebuild. A rebuild would show me how to put the damn thing together I'm just guessing that your eyes are really close together

[@adammcdowell7815]

There is a part 2 that shows the reassembly... guessing you can't read the part 1 part?