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Leak on Fuel/Injector Pump

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bigone
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Joined: 31 Dec 2009
Posts: 48
Location: wiltshire

PostPosted: Wed Jan 30, 2013 20:49    Post subject: Leak on Fuel/Injector Pump Reply with quote

Started car the other day and took out to warm up for oil change. Noted damp patch on drive after ticking over for 10 -15 mins - diesel! took off underpans and, looking up, located a small drip each 15 secs dripping off a light brown connector at the back of the pump, just below the pump centre line. Took off the pump covers and bone dry on the top of the pump (ie where the fuel unions are) and can't see enough of the pump to actually locate the leak! Took to local Toyota dealer on the grounds they might know of the problem - 'if we have to take the pump off to find the problem and replace that's 10 hours work - 800'!!!!! Any ideas what the prob might be before I end up with a massive bill (without pump repairs)?
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PostPosted: Wed Jan 30, 2013 20:49    Post subject: Google Ads keep this community free to join!


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andy
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Joined: 16 Dec 2003
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Location: Polegate, Sussex, England.

PostPosted: Wed Jan 30, 2013 23:19    Post subject: Reply with quote

I have had the same problem, look at this thread http://www.tlocuk.co.uk/forums/viewtopic.php?t=2235&postdays=0&postorder=asc&highlight=tcv&start=15
and give us a shout if you need any more help.
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bigone
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Joined: 31 Dec 2009
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PostPosted: Thu Jan 31, 2013 10:25    Post subject: Reply with quote

That is EXACTLY where I can see the fuel drip - BRILLIANT! Many thanks for the pointer.  Very Happy  Have been on to Toyota this morning and told them to replace the Timer Control Valve before disturbing anything else - only a few hundred quid possibility for a solution definitely beats 800 plus as a starter! I did search for something relevant on the site but decided that leaks in the glovebox were miles from where I had the problem. I would never have thought about the loom cover acting as a conduit (especially defying the force of gravity)!
While on the Diesel Pump and having done some research on removal/replacement I concluded that because of the pullers needed and the re-timing after re-fitting the pump, removal/replacement is not for amateurs - or am I being too cautious? this is the main reason it's with Toyota.
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andy
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Joined: 16 Dec 2003
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Location: Polegate, Sussex, England.

PostPosted: Thu Jan 31, 2013 17:36    Post subject: Reply with quote

I'm not sure that a dealer will change the TCV as they don't sell it, I had to source it from a pump specialist and fit it myself, think I paid around 225 for the bit and took around an hour, that's with tea a fag breaks.
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bigone
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PostPosted: Thu Jan 31, 2013 20:02    Post subject: Reply with quote

Hmmmm...that's probably why I haven't heard from them today. If it's not a Toyota part then they won't have a Toyota standard time to fit therefore they can't offer a warranty or price. I will be on to them first thing tomorrow and can see it is better-than-evens that I will be bringing it home, leak and all, and fitting it myself. Ho-hum!
If I fit it myself is there a need to bleed/purge the fuel system (if so, how?) or just fire it up? Did you need a gasket?
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andy
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Joined: 16 Dec 2003
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Location: Polegate, Sussex, England.

PostPosted: Thu Jan 31, 2013 22:05    Post subject: Reply with quote

To get the correct part you will need the numbers off the tag attached to the pump, then contact a pump specialist that stock Denso parts, I'm sure my part number was the same as in the linked thread.

You will need a good 1/4 inch drive socket set with allen keys and flexible joint, also a mirror that you can fix to something, I kept dropping mine but was lucky it didn't break.

Godd luck.
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It's Not a Bl**dy Jeep it's a Landcruiser
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bigone
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PostPosted: Sat Feb 02, 2013 10:04    Post subject: Reply with quote

UPDATE - Toyota garage confirmed that they cannot get the Timing Control Valve, not stocked by Toyota - complete pump only! Located Denso diesel pump parts supplier reasonably locally and have ordered it (150 + VAT) - arrives Tuesday AM.
Two questions: can you remember if a gasket is needed under the mounting flange and, once the valve is fitted, does the fuel system self-prime? Nearly there! TIA
BTW pump specialist said that this was a common fault with this valve - sometimes Araldite worked to fix the leak (can't be much pressure, therefore?).
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andy
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PostPosted: Sat Feb 02, 2013 10:43    Post subject: Reply with quote

No gasket needed, the unit has an O'ring on the body, and mine started first thing so no priming needed.

Sounds like a good price.
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bigone
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PostPosted: Mon Feb 04, 2013 21:28    Post subject: Reply with quote

UPDATE - latest pain in the rectum is that the Toyota garage say they cannot remove one of the TCV bolts after undoing it (too long) - another bit of block/engine mount is in the way and therefore the bolt and therefore valve cannot be removed without removing/disturbing the pump Crying or Very sad - another 5 hrs work to remove/install - 400! Aaaaargh Shocked I did suggest that the pump might be loosened and swivelled a little like an alternator but they thought it was too firmly located in postion. We shall see..... TCV arrives tomorrow (hopefully).
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andy
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PostPosted: Mon Feb 04, 2013 22:09    Post subject: Reply with quote

Thats a load of Bolloc*s, bring it up to Sussex and I will do it in an hour.
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It's Not a Bl**dy Jeep it's a Landcruiser
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1996 Hilux Surf SSR-G Intercooler Sold
1994 Hilux Surf SSR-V Sold
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andy
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Joined: 16 Dec 2003
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Location: Polegate, Sussex, England.

PostPosted: Mon Feb 04, 2013 22:32    Post subject: Reply with quote

If you PM me your contact details I will talk you through the job, I'm sure you could do it, or as I said I will do it for you.
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It's Not a Bl**dy Jeep it's a Landcruiser
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Mercedes Sprinter 311 Luton
1993 VX80 4.2td SOLD
1996 Hilux Surf SSR-G Intercooler Sold
1994 Hilux Surf SSR-V Sold
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bigone
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Joined: 31 Dec 2009
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Location: wiltshire

PostPosted: Thu Feb 14, 2013 16:02    Post subject: Reply with quote

....AND FINALLY! Got the 4.2TD back last Monday  Very Happy  and so far all seems well. For all those waiting for this valve to leak (I spoke with a diesel pump specialist who says he has experienced many occasions where he has seen this problem) I thought I would post the Toyota fitting cost. Remember the pump still operates ok - you just get diesel dripping from the underpan! The real pig seems to be that you can't remove said valve from the pump with pump in-situ because there is another mount/piece of block in the way of extracting one of the two bolts (at least that is what I was told and looking at the back of the pump on my 1HD-FTE engine it seems highly likely - NO! I am not going to try just yet!). This means that you have to remove the pump, to do this you have to remove the timing cover (because the pump is driven by the cam belt) and remove the cam belt - therefore everything needs re-timing when you put it back together - for this I believe you need Toyota-specific tools!  Shocked Soooo....
Cost of valve 180 inc vat
New Timing Belt 42 inc vat (might as well with the front off)
8 hrs labour @85/hr Shocked  Shocked = 815 inc vat
My total bill was 1073 all-up (includes a couple of small items) because of this b***** leak Evil or Very Mad
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andy
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PostPosted: Thu Feb 14, 2013 17:03    Post subject: Reply with quote

So how do you think I did the job, never removed the pump.

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It's Not a Bl**dy Jeep it's a Landcruiser
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1994 Hilux Surf SSR-V Sold
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bigone
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PostPosted: Fri Apr 26, 2013 13:35    Post subject: Reply with quote

Recently been to Bordeaux and back and all is well with the fuel pump - hope it stays that way! Many thanks for all the help - without which I would have been really stuck. I purchased a telescopic mirror to have a good look at the pump fixing on the side of the engine and, without taking the pump covers off, I can see that there is not much space at the end of one of the bolts and it appears that they are socket-headed bolts which would need a key in the end in order to remove them. I guess it comes down to the size of the tool they were trying to use. At the time my 'degrees of freedom' were really reduced because they already had the car and had disabled it because of the work they had already done to arrive at a diagnosis so I decided to let them finish the work, having been given the solution by Andy. If it happens again (and it's not cold and wet - I don't have it in a garage!) I will give it a go - would be 715 cheaper!
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Super Cayor
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PostPosted: Wed May 08, 2013 11:40    Post subject: Replaced mine, 100% Reply with quote

Hello everyone,

I was lucky enough to find information on this forum and another one (Spanish) regarding this leak issue, and I can say that it wasn't easy to replace but it's perfect now.

I bought the 100 4.2 a few months back and immediately noticed the drops of diesel on the floor when the car was parked. I started looking into the source and there was diesel around the injection pump, and some parts of the chassis, and even one of the engine rubber supports.

When I found out about this forum and looked into my problem, it was clear I had found a solution, so I ordered the Denso valve (cost me 230 with VAT) and did the replacement.

Like so many others have said, it isn't easy for the space is very limited and a mirror is definitely a must, although tricky to look and move your fingers around. The black plastic cover of the injection pump has this foamy interior and it was completely soaked in diesel.

We didn't need to remove the oil filter.

The valve didn't look "damaged", although the base seemed a tiny bit bent (I could be wrong). What drew our attention and maybe explains the leak is the O-ring, it seemed a bit shrunk.

We thought of replacing just the O-ring at first, but what the heck, better safe than sorry so a new valve was fitted.

Everything took us about two hours from start to finish, and then we cleaned the whole engine/front chassis with some gasoline, and plenty of water, so no more signs of diesel anywhere.

This was maybe 3 or 4 months ago and it is absolutely flawless.

Regarding the engine's behaviour, to be honest I didn't notice a change in performance.

So in reality the replacement cost me just the valve price (230), so I'm quite happy with the outcome. Specially when confronted with Toyota's reply to my valve leak issue, which was "we do not have that valve nor do we know which valve it is, we must replace the whole injection pump, 4.000). Yeah right!

Unfortunately we didn't take any pictures of the replacement but I guided myself using what was already published, having read this forum and a Spanish one, so if any owner out there is having the same issue, I'm sure you'll know by now of other stories with photos, i just wanted to share mine and, above all, thank you to all of those who published this very helpful post.

I have a different issue with my 100 but I'll post a new topic.

Thank you very much to the Landcruiser Owners Club and its members!
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