Removing top cover from Injector pump?

[Beefcake]

Hi Folks, I've been asked to repair a fuel leak on a '97 2.5 Diesel Cherokee. I've been told its leaking from the top cover area. I have repaired a number of Toyota's by replacing the o-ring under the top cover and was just wondering if the same could be done here. It's for a family member who's not to flash for cash at the moment so if I can replace the seal without removing the pump for a rebuild, and get him back on the road asap it would be great.
Does anybody have an exploded parts diagram of the pump, they could possibly share with me? ( I have been searching the net with no success yet).

Cheers

[frog53]

Hi Beefcake,

Give this site a go, I'm sure you will find it of some help for sure. www.greatlakesxj.com/tech.html.


David

[Beefcake]

Thanks David, I have found some good info on that site including the service manual.

Cheers
Dan

[MudMonkey30]

I bought a gasket kit from a diesel injection/pump specialist for $90 over the counter.
The top O ring is easy, 5 mins max. All you need is the right size hex attachment for a socket so you can reach from up top, and for the Trilobe bolt you won't be able to buy the socket. So buy a long 7mm socket and tap it on, gently but with force, it won't take much!
Before you do you might want to take a trip to bunnings( the only place that had a new hex head bolt that would fit out of the packet,
Can't remember the exact size now but if ya have time just pull the original Trilobe bolt out and take it with you.
Replace the O ring and use grease to help it seal, some people don't like using grease but I've never had a leak using it on new O rings in any allocation!!
Bolt it back down and away you go!

Bit of advice!
Tell them to start saving and or try and find a good second hand one!
It's $1200 for a diesel pump re-kit, drive in drive out,
You might be able to find a good second hand one for around $500 to $800 bucks...
But ya don't know how long it will last!

Once the top gasket is fixed it's not usually long before other weak spots to eventually start appearing.
Mine isn't leaking yet (6months ago, 3 months of driving) but it's not my daily driver anymore, got a work ute back.

Good luck!
If you can't find a kit let me know and I'll get you there details!
Good honest blokes!

[Beefcake]

Originally Posted by MudMonkey30

I bought a gasket kit from a diesel injection/pump specialist for $90 over the counter.
The top O ring is easy, 5 mins max. All you need is the right size hex attachment for a socket so you can reach from up top, and for the Trilobe bolt you won't be able to buy the socket. So buy a long 7mm socket and tap it on, gently but with force, it won't take much!
Before you do you might want to take a trip to bunnings( the only place that had a new hex head bolt that would fit out of the packet,
Can't remember the exact size now but if ya have time just pull the original Trilobe bolt out and take it with you.
Replace the O ring and use grease to help it seal, some people don't like using grease but I've never had a leak using it on new O rings in any allocation!!
Bolt it back down and away you go!

Bit of advice!
Tell them to start saving and or try and find a good second hand one!
It's $1200 for a diesel pump re-kit, drive in drive out,
You might be able to find a good second hand one for around $500 to $800 bucks...
But ya don't know how long it will last!

Once the top gasket is fixed it's not usually long before other weak spots to eventually start appearing.
Mine isn't leaking yet (6months ago, 3 months of driving) but it's not my daily driver anymore, got a work ute back.

Good luck!
If you can't find a kit let me know and I'll get you there details!
Good honest blokes!

Thanks very much mate, that is great info. I get the vehicle Friday so hopefully it is just the top cover leaking like he's told me. There is a diesel mob close by here on the Sunshine Coast so hopefully they will have the parts otherwise I will chase you up again for the info. Thanks again, much appreciated.

Dan

[Beefcake]

well hasn't this turned into a saga, I was lucky enough for the diesel shop to seperate the kit and sell me just the top cover seal for 10 bucks, got a replacement bolt $2.50, all sweet, got home and fitted it, started the bar stard up and it started leaking under the housing below. Back to the diesel shop got the next seal, another 10 bucks, fitted it, bled air out eventually, battery kept going flat while cranking so had to keep charging it and trying again. Finally got it running and now have diesel p!ssing out the cover on the bottom of the pump housing. It seems like as soon as I fix one leak it causes another. I've spoken to fuel shop and they reckon seals are probably just all due to be replaced, but I just find it hard to believe they would go one after another like this, and all of a sudden. So back to the shop tomorrow for another seal. If it then leaks somewhere else I will be ripping it off and taking it in to be fully resealed at the shop. Think I've done all I can up until now.
I am wondering if it's worth getting the diesel tested, as the tank was filled the night before the leaks started, at an independant servo. I am wondering if maybe they have a cheap cocktail mix in their tanks. It wouldn't be the first time I've seen it. Sound like a worthwhile plan to anyone?

[MudMonkey30]

It's worth it in the long run, atleast you know not to Ever go back to that servo!

I did mention that once one seal was fixed it's highly likely the rest will go.

I try to keep away from Any type of blended / Bio Diesel anyway,
I know for a fact that all the original seals and gaskets were not designed to run bio fuels!
Anything under 4 years old should be ok but I would check with your mechanic or reputable injection specialists!

It is highly likely that the "independent servo" has a nice cocktail going on...
Even this ultimate diesel is shit.
My 2c