I have a 82 240 with the D-24 diesel engine, and have just discovered that the injection pump front seal is leaking signifigantly. I have a fair amount of experince with gasser volvo, and with other types of diesel engines, but not with these particular engines. So, I have come here. First of all, can you just replace the fropnt seal on the injection pump, or would it require the pump to be torn down? If I can't replace the seal, any recomendation on where to get a good used pump? I do not really want to fork out the $$$ for a rebuilt or new unit. The current one seems to work just fine, except for that leak. Also, how hard is it to remove and properly replace the pump? I have a service manual, but it calls for a number of tool which I do not have. Has anyone had expoerince doing the job without the special tools? Also, if I get a 740 (turbed) pump, is there a way to turn the fuel down so it does not overfuel? Will the boost pressure sensor thing work to that extent? (that is, if it's not conected, for the equivilent of no boost, will the full throttle injection amount still be the same as a na engine??) Baring that, is there an easy ajustment on the fuel limiter? I have a fdair amount of experince with the IH diesels in 80's ford pickups, and on those engines, there is a fuel limiting screw that's pretty easy to adjust, and it's pretty easy to adjust it to where you just start to get black smoke under full throttle.
Thanks ~ John

A turbo pump has different parts inside it, atmospheric compensation, and needs different injectors -- the bane of all diesel pieces stamped on them. The rebuild shops know what each stamp marking means, and overstamps if they change parts. The prior advice was great, only when you put it on, loosen the pump fuel input line and gently pressurize the return line to the tank to prime everything, saves on battery and starter. Also, be sure you are at TDC if you have to start over as there are two marks on flywheel. I do a mandatory turning engine with wrench on crankshaft pulley a couple of complete turns to know I had all timed right (I didn't and felt a valve rather than crumping one with the starter). Finally, I do not fully tighten injector nuts until I see diesel pulsing out without bubbles when I try to restart the engine. As you tighten the bled ones, it will start to run and then tighten them all. Happy rattling :)

It's not too horribly difficult to remove the pump, but there are a few tools you will need
The seal can be replaced without too much difficulty, but if you don't already have the special pump gear puller, the easiest thing to do is remove the pump bracket to block mounting bolts ( this is tedious for the two directly between the pump and the bracket, the one below that holds the dipstick tube as well is easy to reach with soclet and extension soak the bolts with Aero-Kroil for a couple of days before starting incase the last gorilla to work on it overtightened things )

First remove the belt guard, turn engine to tdc #1 there should be a mark on the pump gear and the small hole in the gear will line up with the hole in the pump bracket,Take a marker and mark EXACTLY where the pump lines up with the bracket, feel the belt tension so you can get it close on install.Remove the injector lines( at least a 17mm flare nut wrench needed, a 17m flare nut crows foot wrench comes in REAL handy, about $20 from snap on ) then loosen the pump bracket pull the belt,Remove #6 glow plug wire, pull the pump bracket bolts all the way and wrangle the pump out with the bracket.

Now take the whole works to a diesel injection shop and pay them to pop the gear off, and for a few bucks more, just replace the shaft seal ( either that or buy the seal and replace it yourself, not hard, but you know they'll get it right, after yanking that pump, you'll be seriously considering paying them :-)

Replace is the opposite, HOPEFULLY you will get it close enough to run, but if not, you'll need to buy a timing gauge

I'm not sure about trying a turbo pump, but I have a bad feeling about it.I think the internal cam is different.
.Don't waste your money on a used pump, you'd most likely just be buying a rebuildable core...which is what you already have.
------------Robert
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-------Robert, '93 940t, '90 240 wagon, '84 240 diesel (she's sick) , '80 245 diesel, '86 740 GLE turbo diesel, '92 Ford F350 diesel dually