Injection pump removal and refitting

I would really appreciate some advice please before I start on this job.

The injection pump is leaking. I think I have traced it to the joint between the distribution block and main body. Quotes average c. £450 to get the pump off and put it back on and c. £200 to have all new seals fitted plus calibration checks from a specialist ( I have been recommended here www.parkinsons.co.uk/Peterborough ). I'm thinking about doing the removal / re-fitting myself to save money. I can get my head around most of the work except...

..when removing the pump I plan to have all the timing belt marks in their requisite places but when it comes to putting the pump back on does it matter that it's shaft will have been rotated? Do I just align its timing mark and put the belt back on? It feels like it should matter but how do I get the pump rotation in the right place? ie so it delivers fuel to the pistol that is about to come to its firing position.

..after removing the timing cover is it possible to put bolts through say the cam belt wheel to lock it in place (I just needed M8 bolts on a citroen some years ago). This would obviously help lock it all in place

.. I read the thread from Breadbin in 2008 (Fix leaking pump the cheap way). As my Hiace seems to start and run well (she's no F1 but then I've never driven any other Hiace, and she's done 200k km) maybe I could just get a seal kit (c.£15) and I reckon I could follow Breadbins instructions. Loosening (not removing) the distributor head studs and easing the seal over sounds a bit nerve racking in case something goes ping inside but has anyone tried it. That could be a further c.£200 saved ..or maybe a saving too far?

Any suggestions / tips / pitfalls to avoid would be very much appreciated please. I'll take some photos and keep a log with a view to posting my experience although when I fixed my starter motor 'clicking the other week I couldn't get the photos uploaded so maybe more advice on that is needed. I'm better with a spanned honest!

Thanks in advance.

PS - If anyones interested I found what seem like great schematics for every bit of the Hiace (including the pump) here...
www.megazip.ru/ru/auto/toyota/view/494/4521/43648/418905#g418908

and for the denso pump here
www.vepump.com/Repair_Kit.htm

Just mark all the timing points on the belt - copy accross to new one if one is to be fitted.

Remove pump pulley, it is on a keyway and will only go back in the same place, remove pump and overhaul, the pump can be rotated back into the correct position after you have worked on it.

Have a go yourself, the worst that can happen is you end up taking to the specialist in pieces, the best is you save a fair bit of cash.

Thanks for the reassurance Clive. Marking the belt as well as locating timing marks sounds sensible.

Just to be clear. If I rotate the pump when back on the engine to get the mark on the pump pulley (which is now wood ruffed onto the pump) lined up with the others couldn't the pump be 360 degrees out? As long as that doesn't damage anything when i try turning it over then I guess all I have lost is a little time to remove the timing cover/belt, rotate 360 degrees and put it back on. Is that right?

Sorry to be a pain but I'm trying to understand this before I get it all in pieces!

Cheers

Pump position will not affect anything mechanical/expensive.

i guess that's all i needed!
I'm planning on doing the job week after next and I;ll report back afterwards.

Many thanks

Hi Camperman,

Just trawling through posts as I have a fuel leak from the pump on my 3L engine.

Did you have any success in fixing this? Mine seems to be leaking at a joint between the distributor block (the bit the injector pipes screw into) and the main body of the pump.

Any advice much appreciated.....

Cheers

P

Major strip down to replace that gasket I'm afraid.

If you are handy with spanners not that complicated to do, no special tools needed. There was a how to do it on the hilux site.

Many thanks Clive,

Don't suppose you have a link to the 'how to' by any chance.....

Cheers

P

Quick Google came up with this -

http://www.vwdieselparts.com/forum/viewtopic.php?t=6694&highlight=bosch+epve+stripdown

Toyota Denso pumps are Bosch under license.

Hi, i am new to your forum, and straight away two of us(Camperman) wanting to remove the injector pump and asking the same question, specially when putting the pump back if it can be 360 out. i need to get it right first time as its a pain to remove again, is there a way of telling before i put on the timing belt, maybe checking the spill-timing on No 1 cylinder.
My reason for pump removal is black smoke under load and change of gears, would like to send the pump for overhaul?
Also please may you help, my timing light came on at 60 000km as i was far from home i drove it another 2010km, all of a sudden all the lights came on the dash and a continues buzz, but the engine was still idling as normal, as my wife put it, she switched off the engine. i did not try to start it again, suspecting the timing belt broke, opened up T/belt cover found timing belt as good as new,
so i have decided to change belt kit and service pump, do you have any suggestions please why all lights came on. its a 2.8l 3L 1996 Toyota Hiace 4x4 truck(Japan). where do you reset the timing light.
Thank you so much for the help.

Many thanks Clive - wasn't sure what to google for.....

Looks quite complex so I may have to bite the bullet and get it to a specialist.

Cheers

P

All dash lights on = no alternator output, check drive belt.


If only is was easy to get a spare pump to try an overhaul on!

Thanks Clive, all belts seem to be OK, waiting to order spares, t/belt kit and send pump for service, stripped most stuff off already.
Found the two holes, i hope it's the right ones for the timing belt light behind the dash close to the speedo cable connection moved the screw to the next hole, will check when i put all back.

i have a leak on my 3ltr turbo diesel it is at the censer how do i fix can i doit my self with out killing the injectors thanks

I would like to thank all for the advice on the problems i had, injector pump, lights all coming on, timing belt light
i bought a timing belt kit with water pump and changed the whole lot myself, got the injector pump serviced.
Sorted the timing belt light out, fitted a new alternator and all is working well again, i have learned so
much and know my car much more.
I can now share with others what i have picked up. thank you.

Clinton.Daddy wrote:

i have a leak on my 3ltr turbo diesel it is at the censer how do i fix can i doit my self with out killing the injectors thanks

Yes you can fix it yourself. Which sensor it may just be a sealing ring that needs replacing?

Langie wrote:

I would like to thank all for the advice on the problems i had, injector pump, lights all coming on, timing belt light
i bought a timing belt kit with water pump and changed the whole lot myself, got the injector pump serviced.
Sorted the timing belt light out, fitted a new alternator and all is working well again, i have learned so
much and know my car much more.
I can now share with others what i have picked up. thank you.

And thank you it is nice to get a thank you every now and then. Oh and good for you well done.
I'm not a mechanic, although I feel I know more than some of them......
My first cars I had to fix by myself, at the side of the road with limited tools, steep learning curve, I have since gained lots of knowledge. I've had a Toyota for the last 20 years, all MPVs and all put together in much the same way. Parts identical just different sizes. I have got it wrong on a few occasions but against a vast majority of getting it right, I feel that I've saved a huge amount of cash and have the satisfaction of knowing it has been done right.
Getting old now so I've had to use a garage now and then for heavy jobs, but hey I've the funds now so no great problem.
Don't be afraid of the vehicle it is just a large box of parts that you build into a working machine.