IP Leaks only when Cold? Shaft Bushing Gone? - IDI Engine - VWDiesel.net The IDI, TDI, and mTDI source.

• IP Leaks only when Cold? Shaft Bushing Gone? by Ziptar on 24 Jan, 2008 02:48
• I noticed I have a new IP leak yesterday morning. After the car reached operating temp it was gone.
  
  Same thing happened when I left work, it was leaking when I started it stopped when it heated up.
  
  Saturday I'll see if I can track it down, right now I can't see exactly where it's leaking. seems to be over near the advance shaft but can't say for sure.
  
  Based on how it behaves I have a sinking feeling its the shaft bushing and that as the pump warms and expands it eventually seals.
  
  Hopefully its not and I can pull the pump and reseal it, I have the rest of a DG 126 seal kit from when I did the o ring for the pump head. I don't have a 17MM shaft seal though, anyone have a part number? I want to see if I can get one locally or quickly via the internet.
  
  
  Thanks,
• #1 by burn_your_money on 24 Jan, 2008 05:15
• vortex is down right now but a guy by the name of ryan_wankel (probably not spelt properly) sells the kits
• #2 by myke_w on 24 Jan, 2008 05:23
• I have those seals, but they are a real *** to get out without gouging the housing.. I have the tool to do it on the car with the pump in place... I can rent it to you if you are interested...  Let me know, it could ship today if all the pieces come together...
• #3 by Quantum TD on 24 Jan, 2008 10:53
• More often than not, the pump will be leaking out of the cold start lever. I just had to do that trick on a 1991 ECOdiesel about 2 months ago.
  
  You can buy just that seal (VW PN # 068198 052A). It includes the seal for the front of that shaft tube, and the back: where the lever actually attaches.
  
  You can try to do just that, but chances are the other seals will start leaking soon afterwards.
  
  If you dont' mind being down for about a week and you don't want to tackle it yourself, you can send it to (ebay name) red--rider for a $150 complete reseal.
• #4 by Ziptar on 24 Jan, 2008 18:02
• Ok, so the cold start advance seals aren't in the DGK121 Kit? I need to get them? I'd send it to red--rider but, the down time is an issue.
  
  I was thinking since I already did the head seal with it on the car I'd pull it and do the other outer seals and put on a fresh timing belt and idler.
  
  myke_w, I may rent the tool from you and get a seal, mucking up the housing gives me the willies but, I survived replacing the head seal. :lol:   I'll track down an advance shaft seal kit if need be so I have it all ready to go on a weekend.
• #5 by Quantum TD on 24 Jan, 2008 20:03
• Quote from: "Ziptar"

  Ok, so the cold start advance seals aren't in the DGK121 Kit? I need to get them? I'd send it to red--rider but, the down time is an issue.

  
  
  The cold-start lever seals ARE included in the DGK 126 kit (and probably in the 121 too). If you already have the kit, but just used the head seal, then you should have the lower seals for both sides of the cold-start lever covers.
  
  Here's a pic from worldimpex so you can reference your DGK kit to find the seals that you need:
  
  http://www.worldimpex.com/parts/genuine-part-bottom-gasket-set_44323.html
  
  I just suggested this 'mini-kit' if you wanted to just try that part first and see if it would solve your problem. This mini kit is cheap (about $10 at your dealer). That, and in my experience, the seal leaking follows a standard format:
  
  1st: cold start lever cover starts leaking slightly (moist)
  2nd: distribution head seal (that you've replaced) starts leaking just enough to show wetness
  3rd: throttle cover starts leaking (moist)
  4th: cold start lever seals start POURING out.
  5th: Input shaft starts leaking (rare from my experience).
  
  You can probably live with 1-3, but 4-5 are a bit harder to live with. So, if you've done the dist. head seal, and the input shaft area looks dry, then do the cold-start lever check and see what happens. I don't think that doing the whole pump would be that bad either. The top cover just requires you to make some reference marks. So, if you've got it off...
  
  Let us know how it goes.
• #6 by Ziptar on 25 Jan, 2008 02:28
• Excellent, Great Info!
  
  Heh, my brain is going as well as my IP. :lol:
  
  I just grabbed the kit out of the tool chest, It's a DGK 126 not a 121. The seals pictured on World Impex are in the kit. At least look to be.
  
  I just figured I'd do them all. Take it out, do the T-Belt and Glow Plugs too. Ok, I'll get my parts ordered.
  
  myke_w You have a PM RE: Tool Rental and Input Shaft Seal.
  
  I post back when it's done (probably next weekend).