Version: 1.5

Author: Duncan Margetts

Source URL:

https://docs.google.com/document/d/19SHlXDMITHS1WiQXQa40kXlhrL2GIVzEpbyqhJ73XFk/edit?usp=sharing

Symptoms of a leaking delivery valve

• Diesel leaks on the injector pump at the point below where the rigid fuel injector lines screw onto the pump.

Gasket Part Number: Toyota 22149-76010

Potential Suppliers:

• Toyota

Tools required:

• 17mm Flare Nut Spanner set
• Pair of needle nose pliers
• Torque wrench
• Wire brushes
• 22mm ring spanner or deep socket

There are 6 delivery valve gaskets, one for each cylinder, they sit underneath the Delivery Valve Holders. They are plastic and about 3mm thick. A Delivery Valve Holder is shown highlighted in this image:

Before attempting this repair:

• You should first try marginally tightening up the leaking Delivery Valve Holder, it will often resolve the issue. The rigid fuel line needs to be loosened and the clamp removed first though (Steps 1, 2, 3 and 4). Retorque the Delivery Valve Holder (375 kg-cm (27ft-lb, 37Nm)
• Verify that the leak is not from the rigid line attachment to the top of the Delivery Valve Holder, again a minor tightening may resolve it.

This repair CAN be done whilst the pump is still installed on the engine. It is essential that great care be taken to clean the area on the pump around the Delivery Valve holders as thoroughly as possible you should degreaser, small wire brushes, rags, compressed air etc. It needs to be as clean as you can possibly make it. The part that is being changed is shown below.

Step 1: Thoroughly and completely clean the top of the injector pump.

Step 2: Clean the top of the injector pump, again. It should look at least as clean as this:

Step 3: The rigid fuel line on the offending delivery valve gasket needs to be removed. A flared nut spanner should be used to undo the rigid fuel line. A flared nut spanner looks like this.

Shown below is the nut that must be undone to remove a rigid fuel line. Please note that BOTH ends of the rigid fuel line should be undone and the rigid fuel line set aside. Dont be tempted to bend it out of the way. If you’re just going to tighten the holder, its sufficient to loosen the fuel line, no need to remove it.

Step 4:  Remove the Delivery Valve clamp, it’s shown below. A 10mm socket is used. Only the clamp holding the Delivery Valve Holder that’s leaking needs to be removed. They are paired up. So one clamp holds two Delivery Valve Holders

Step 5: With a 22mm Ring Spanner or a 22mm Deep Socket the Delivery Valve Holder can now be removed. It will be very tight. Make sure you’re removing it the right way (righty tighty, lefty loosey). When the Delivery Valve Holder is loose, use your fingers to gently unscrew it, as you lift it up there will be a long spring, do not lose this. What you will see is this:

Store the Spring, and the Delivery Valve Holder somewhere, and before reinstalling make a good effort to thoroughly clean these.

Step 6: With the Delivery Valve Holder, and the Spring set aside you will be seeing this:

The highlighted part is the actual delivery valve. We will be removing this in step 7.

Step 7: The delivery valve must now be removed. it’s shown in the photo below. Great care must be taken with its handling. Do not touch it with your fingers, place it straight into a very clean container. Do not handle it. If you are doing multiple gaskets at once make sure that the valves go back into exactly the same injection port they came out of.

To remove the valve use a pair of needle nose pliers and lift it out. take great care not to drop it. You may wish to put some rags behind and around the pump to make sure it's not lost if inadvertently dropped. Treat this part very gently, it’s machined to a high tolerance.

Step 8:  The actual Delivery Valve Gasket is mounted on the “Delivery Valve Bore”. Both parts are shown below. You can see the Delivery Valve Bore whilst it's still mounted in the delivery port photo above. The gasket cannot be removed whilst the Delivery Valve Bore is still in the port.. the Delivery Valve Bore must be removed to get the gasket off it. This is described in Step 9.

Step 9: To remove the Delivery Valve Bore, on which the plastic gasket is mounted, you need to find something that matches the external thread of the bore and use that to grasp it for removal. It's a light interference fit, with a small amount of force it can be pulled up. Toyota use a Special Service Tool to do this. I use an air hose fitting as you can see below. Under NO circumstances should any tool be inserted into the actual bore itself. The internal surface of the bore is highly precision machined and must not be touched.

Step 10: Once the Delivery Valve Bore has been removed the gasket can be eased off the part, a new one can be installed and reassembly can begin.

Step 11:  

• Using whatever tool you used to remove the Bore (the air fitting in my case) reinstall the Bore complete with its new gasket into the delivery port.A light tap on the top of your tool with a very small hammer will help seat it properly
• Reinstall the small Delivery Valve.. again taking care not to touch it with bare fingers.
• Reinstall the cleaned Delivery Valve Holder and Spring, make it finger tight.
• Torque the Delivery Valve Holder to 375 kg-cm (27ft-lb, 37Nm)
• Reinstall the rigid fuel line.
• Reinstall the Delivery Valve Holder clamp

Step 12: You may need to bleed the injector lines you’ve undone. Mostly the 2H will self bleed its own injection lines. I would try the self bleed first by starting the vehicle and allowing it to run roughly for a little while until the line bleeds. If this fails, you’re going to have to loosen the rigid fuel line on the injector and crank the engine until you see fuel squirt out from the line then retighten it.

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