Hello all from across the pond,

My "creampuff" Defender 1991 200TDI just developed a large fuel leak in the middle of the injector pump. I understand that it isn't possible for me to rebuild it but my Haynes repair manual has quite a few steps to remove this pump including some timing issues and a few special tools that I would never be able to get over here. I am a decent mechanic but I have never had any experience with replacing an injector pump. How difficult is this job? Can I make some tools that are needed ? Where is the best place to purchase a rebuilt pump? I am sure they will require my old one or I will incur a large core charge. Thank you for any insight!

The cheap (under 40 dollars) tdi timing kits off of ebay include a large black round puller which willl also hold the inj pump sprocket in position without removing the cambelt/timing covers etc. but I have always just removed the covers and fitted a new belt.
You can do it without the timing tools (mark crank and use a drill bit in the inj pump) but it is much easier with them you only have to pin the crank and the inj pump the cam you line up two marks, the only real problem with removing timing cover is them three bolts around the water gallery as they can seize/snap, so my top tip would be to see if they come loose one at a time then decide which route to take.

People have replaced the inj pump o ring that leaks in situ, but there are risks ie you undo the bolts to far and the pump falls to bits!

I bet island4x4 could ship the timing kit and belts/tensioner to you for not to much money?

Examples off ebay

https://www.ebay.co.uk/itm/370727231585?epid=1251340398&hash=item565110a061:g:OGYAAOSw4ulgtgsd

https://www.ebay.co.uk/itm/194074570592?hash=item2d2fbeef60:g:xqEAAOSw9Shgilot

Kiteboarder Ken said:

Hello all from across the pond,

My "creampuff" Defender 1991 200TDI just developed a large fuel leak in the middle of the injector pump. I understand that it isn't possible for me to rebuild it but my Haynes repair manual has quite a few steps to remove this pump including some timing issues and a few special tools that I would never be able to get over here. I am a decent mechanic but I have never had any experience with replacing an injector pump. How difficult is this job? Can I make some tools that are needed ? Where is the best place to purchase a rebuilt pump? I am sure they will require my old one or I will incur a large core charge. Thank you for any insight!

Click to expand...

There are several ways you can go with it.
Mostly depends on how long ago you think the timing belt was changed, and how worn the injector pump is.

If you know that the timing belt has been changed recently, and think the injector pump is good apart from the leak, you could just use a pulley holder, as @lynall describes^^^^^, remove the pump without disturbing the belt, and try and replace the seal. There are many guides on the net, and in print, as to how to do this.

If you think the belt is in good nick, but suspect the pump is very worn, you could remove the pump, using the pulley holder, and take or send the pump to a Bosch agent, who should be able to recondition the pump.

Or, if you are unsure when the belt was changed, you could use the pulley locking tools, remove the pump and get it fixed, and then replace the belt and tensioner with new, and go through the tensioning procedure, also well described in manuals and online.

Personally, I never mess around with pumps, with the exception of a few very simple jobs on the outside of the pump. I assume that is it is leaking in one place, it will shortly start to leak elsewhere, or show other problems, so I just send them off for test and recon. There is a firm called Diesel Bob in the UK that does this, reasonably good value. But I don't know how cheap mailing a pump from the USA to them would be.

You can get a bit if an insight into likely injector pump condition by examining the rest of the fuel system. If there is a lot of water and crud in the tank, lines, and fuel filter, chances are some of it will have found it's way into the pump, and caused damage.

If in any doubt about the belt, or if there is a lot of oil in the timing case, it is probably better to replace the belt while you are removing the pump anyway. I always use Gates belts, but don't know anything against other makes, just that I haven't had a problem with Gates.

Thank you gentlemen for your input. Hopefully I can find someone over here close enough to do this job, if not, looks like I will be giving it a go. Seems easier for me to change the entire engine though.

Kiteboarder Ken said:

Thank you gentlemen for your input. Hopefully I can find someone over here close enough to do this job, if not, looks like I will be giving it a go. Seems easier for me to change the entire engine though.

Click to expand...

Do you have a picture of the exact place it is leaking?

Cheers

@Kiteboarder Ken

This is the sort of kit you are looking for.
https://fourby.co.uk/epages/950004277.sf/en_GB/?ObjectPath=/Shops/950004277/Products/"Timing Kit"

And Britannica restoration on youtube or trailerfitters toolbox have some great vids on how to remove / strip the pump if required. It is not that difficult.

Cheers

One way,
And a bit about leaks, ,
Check out more videos on his site on injector pumps. Or anything else about Defenders.