Help removing fuel injector pump cover

[chemist]

HELP!
Started to install a throttle shaft oring to stop a bad leak, removed throttle springs, etc and the 4 bolts holding the cover down and started to lift cover up but it would not come up more than an inch, caught on something internally, but if I try to re-seat the cover it will not go down.

Now I'm without a seal, without a working IJ pump and car.

Can anyone tell me how to get this cover off correctly so I can replace the throttle shaft oring and put the cover back on again correctly?

This is a Bosch VE pump on a 1991 VW Jetta non turbo.

Thanks so much,
Perhaps a phone call would be more efficient? (days 508-854-5286, eve 508-248-7281)

Brad

[chemist]

More info: Help!  "Can not remove injector pump cover"



img=4446_injectorpumpdiagram.jpg.html

[Vincent Waldon]

Coupla thoughts... in approximate order of likelyhood:

- are you pushing out the throttle shaft as you lift the lid ??  The throttle shaft stays attached to the body of the pump during lid removal.. you may need to use a drift to help press it out as you lift the lid... and depending on condition of the throttle bushing and o-ring (already suspect since it leaks!) it may take a little bit of pressure.

- have you backed out the fuel screw (the screw on the driver side that is sealed with a lead or plastic cap) ??  Sometimes that screw hangs up during disassembly (it certainly will try to do so during assembly)... be careful to count the exact number of turns or just ensure you don't move the locknut against the steel/plastic seal.

- does your pump have a linkage on the backside  (the side that faces the engine) which bumps up the idle when the cold-start knob is pulled out all the way ??  If so there is an internal spring between that linkage (looks like a teeter-toter that rocks between two adjustment stops) and the throttle arm internally... gotta look up inside and remove one end before pulling the lid completely off.

[chemist]

Coupla thoughts... in approximate order of likelyhood:

- are you pushing out the throttle shaft as you lift the lid ??  The throttle shaft stays attached to the body of the pump during lid removal.. you may need to use a drift to help press it out as you lift the lid... and depending on condition of the throttle bushing and o-ring (already suspect since it leaks!) it may take a little bit of pressure.

- have you backed out the fuel screw (the screw on the driver side that is sealed with a lead or plastic cap) ??  Sometimes that screw hangs up during disassembly (it certainly will try to do so during assembly)... be careful to count the exact number of turns or just ensure you don't move the locknut against the steel/plastic seal.

- does your pump have a linkage on the backside  (the side that faces the engine) which bumps up the idle when the cold-start knob is pulled out all the way ??  If so there is an internal spring between that linkage (looks like a teeter-toter that rocks between two adjustment stops) and the throttle arm internally... gotta look up inside and remove one end before pulling the lid completely off.

Thanks Vince,
       I did get it off just fine with your help and back on again, now no leak with throttle shaft, but have a leak at the cold start bolt on engine side just below the parting line with the cover, don't know if I can get to that with the cover off again and without changing the timing.

Also, it now idles very very rough, I had to really increase the idle screw to stop it from shaking like a washing machine!  Drove it to work today, better when warmed up but still the rough idle.  Could this be a clogged injection port or did the fuel screw mess up??  How would I check the fuel screw to re-ajust?  Carefully I assume, but make the adjustment while it is stopped then start and check it out?

Thanks,
Brad