Archived Help KSB won't stop leaking fuel !

[quiksilver1j]

Ive got a 1993 12v with VE Injection pump. The engine & pump were rebuilt about 4000 miles ago with lots of upgrades... Hamilton 188/220 cam, big S300 (64/72) turbo, 5 x .012" injectors, M&H timing advance spacer... which leads me to my problem.

Last week I noticed fuel dripping from my vacuum pump and traced it to the ksb housing. Fuel is leaking between the m&h timing spacer and the ksb at a rate of 1 drip every 10 seconds or so. I confirmed it was leaking from the ksb flange by watching it drip with the help of a dental mirror.

I tried removing the timing spacer but the ksb still drips at the same rate. I tried replacing the o rings even though the ones provided with the M&H timing kit seemed to still be in perfect shape. To the best of my knowledge this wasn't an issue until 2 weeks ago.. only thing I did around that time was to turn in the main fuel screw 1 turn. Turbo spooled up faster, EGTS actually went down on the highway, truck ran great! I thought all was good.

I checked the ksb housing for any obvious cracks but can't see anything. I just don't know what else could be causing this flange to leak.
The engine runs perfectly, same as it did before, just leaks fuel, What am I missing? Could the pressure regulator in the injection pump connected to the ksb be stuck open ? or clogged?

Tomorrow I plan to remove this regulator valve and the banjo bolt on the fuel return line to make sure both aren't clogged and function properly, any constructive ideas are appreciated!

 

[AnonEd]

The pictures are no longer there but this is from a 10-yr-old thread...and don't know if of any help...
For you all out there that do this on a regular basis this leak fix is a piece of cake. I am not a diesel mechanic nor do I have automotive maintainence training, I just need my truck to run reliably. That being said; I remember about cleanliness first, on injection pump systems. I flushed off the outside and wiped down the work area with a lint free cloth. Removed the plug. No fuel leaked out. Part number 3 and 4 in the exploded view were the subjects for replacement. Inspected #3 o-ring that was captured on the plug shank. Measured it with a vernier caliper to match it to a new o-ring in the DGK-121 kit. The #4 o-ring stayed in its seat in the pressure control module bore. Stripped a piece of copper electrical wire and used a dental mirror and removed the stuck o-ring. The #3 o-ring was cracked and flattened and very brittle and the #4 o-ring was severely flattened. Located o-rings in the kit that were oversized in OD and undersized in ID by a slight amount. Soaked everything with MMO and assembled the o-rings to the plug. Screwed the plug back into the housing until it got tight. It was still quite a ways from being in position but the #3 o-ring had not seated as yet. When that slipped into its seat the plug got loose again. I tightened it until it seated with a pressue measured in 'THUMB POUNDS". Anyway, IT DONT LEAK NO MO' I hope this helps others out there with the same problem. BTW the plug appears to have a ball and spring check or relief valve in it. I dont know if there are parts or a replacement available for this. GregH