(Home) Inj pump fuel leak

Hello chaps! My 91 "Royal Lounge" Townie diesel has a leak coming from the injection pump somewhere around the front/left. There are so many hoses and identifying exactly where it originates is tricky. Is there a common "leak source" on these Inj pumps? There is what appears to be an advance box cover which is most suspect, are these known to leak? (It's in the same place as a Delphi adv box would be anyway.) Its an oval"ish" cover with 2 fastenings and what appears to be a threaded adjuster with a lock nut protruding from its centre. What a marvellous forum this is!

- (#9517) Mark Harriott, 23 Mar 04 14:18

Hello Mark.
Yes it's quite common for these pumps to leak, particularly around the 80k miles mark.
There is information on Ace Answers under Fuel system/fuel leak from injector pump. Or copy this to your address bar. http://mpvi.net/ia/ia001410.htm

- (#9517) dave Bright (Bournemouth), 24 Mar 04 01:51

I'm getting a chap to change the cam belt soon and he thinks it would be good to get the pump to a specialist at the same time. It's done 80k km and from previous experience, (french car), it'd be better to do the cam belt early! I wish manufacturers would bring chains back! I'll let you know how it goes. Thanks for the info.

- (#9517) Mark Harriott, 24 Mar 04 19:30

When your chap does the cam belt, get him to do the water pump at the same time. ADL replacement costs less than £40 and as it runs off the back of the cam belt, its a long job to change it if it fails any time soon.

- (#9517) dave Bright (Bournemouth), 25 Mar 04 01:15

Mark,

Just read your post, had what sounds like a very similar problem happen to me a short while ago.
Diesel was leaking from the front left of the Injection pump, I traced it to the governor cover gasket, replaced it & cured the problem. (Gasket only a few quid if I remember).
You will need to have the injection pump timing reset, as its impossible to replace the gasket without messing them up.
Be careful if you entrust this job/fault finding to a "diesel specialist", as when I did, they tried to tell me my bus would need parts, pump stripped & rebuilt/calibration etc, total cost £500 - £600.
Did the job myself, paid for a trusted garage to reset the pump timing, cost me £30 all in, bus runs great - no fuel leaks.

HTH, Tony

- (#9517) Tony LLoyd-Jones, 4 Apr 04 14:03

Thanks Tony,

I believe you're spot on with the leak source. I've just been crawling all around the engine bay and the pump is comparitively dry above this joint.

It's just failed the MOT because of the leak (plus some lights, which worked fine once the "vanished" fuses were replaced, how mysterious!)

Is there a good schematic of the pump anywhere so I can see what's involved. I believe there must be a spring underneath to dis/reconnect, is this tricky?

.....And is there any info on the gasket part # or are they generally available from autoparts stores?

(I hadn't planned to do the cambelt just yet as wifey needs the townie for work at the mo)

Cheers chaps

- (#9517) Mark Harriott, 13 Apr 04 12:39

Well I got a seal from "Potteries Diesel" plus the throttle shaft seal fot a total of £2.88 and all was going well until part of the spring assembly broke on re-assembly.

I spent 3 hrs looking for the broken bits and then decided to take the punp off and to "Potteries diesel" to make sure no bits were in it and for complete resealing.

I'm doing the cam belt at the same time.

I intend re-loctite ing the crank bolt, will this do?

I'm having trouble seeing any timing marks on the crank pulley so I marked it myself, are there better timing mark on the sprocket? I've ordered a puller so haven't got the pulley off yet?

I think I'd better get a manual too!!

I'll keep you informed. Wish me luck please!!

- (#9517) Inj Pump Fuel Leak, 15 Apr 04 07:28

Mark,

All illustrations are in the Toyota engine manual. Can be done at home if you're confident enough, very fiddly & awkward job though. Be especially careful when lifting the governor cover off, as this is when things can go "pete tong"! If you want any more info I could look it up for you, even e-mail you a step-by-step guide as to how I went about doing this job, but it won't be until next weekend though, as I'm away in the week.

Good luck with the job, Tony.

- (#9517) Tony Lloyd-Jones, 17 Apr 04 15:47

i trust you ordered the correct puller- bolt on, not a legged one...

- (#9517) David Miller, 17 Apr 04 16:18

3 legged puller seemed to do the job with ease! The crank pulley just slid straight off with no real effort. (I had pelted it all around with a plastic hammer first tho.)

Found the crank pulley timing mark with my fingernail after seeing the pointer.


The FIP came back within 24hrs and everything assembled with the new cam belt in good time. The manual arrived just as I was finishing off on Saturday morning! I did forget to pick up a new fan belt so I'm expecting it to fail as I had to refit the old one. Although it looked ok, I know they can fail after re-fitting.

Worst parts were re-fitting/wrestling the drivers seat into the slider rail and the heavy rain dribbling down my bum cheeks!

If it lasts the week I'll do the fan belt next W/E aswell as an oil change.

Seems to drive ok, maybe a bit better than before and the fuel leak is cured!

I didn't change the water pump tho due to additional cost and the present one seems fine at the mo. Are there early indications of water pump failue or an estimated mileage to failure? Wifey has strict instructions to stop if the temp deviates above normal, even slightly, and call the AA for a tow.

Re-MOT set for Wed pm.

Thanks for all your help chaps.

- (#9517) Mark Harriott, 19 Apr 04 06:13

Unfortunately the driver needs to stop BEFORE the unmodified Toyota temperature gauge deviates above normal.

Consider fitting the Ace Answers modification which overcomes this problem by improving its sensitivity and providing an audible alarm so you don't even have to watch it all the time.

- (#9517) Dave (Sussex), 19 Apr 04 09:11

Cheers Dave,

I certainly will now!!

Is the gauge not accurate/reliable? I didn't know they were misleading. I might fit a thermocouple and digital readout too! I was always impressed with its "rock-steadiness". I'll have a look at Ace Answers!


- (#9517) Mark Harriott, 19 Apr 04 10:22