AAZ Injection pump head o-ring seal kit

[Sam Johnson]

I want to replace the injection pump head o-ring on my AAZ engine with a Viton one.  I also would like to do it without removing the pump.  

Does anyone know where I can buy the o-ring seal??  Is it possible to do this without removing the pump??  I have seen a technical article for doing this on the TDI.  Can I also do the same thing on the 1.9TD AAZ engine injection pump??

Thanks for your assistance.

Regards,  Sam
Tucson, AZ

[burn_your_money]

It can also be messed up easily and will trash the pump in a hurry if done incorrectly.

Very, very easily. There are springs in there that could fall out of the head and then you're in trouble. Plus if you get any dirt or rust in there... well

Why do you want to change it?

[Sam Johnson]

Andrew and Tyler,

Thanks for the response.   I have a very slight leak from the IP.  It appears to be leaking at the o-ring.

I carefully read the material from Andrew and was pleased to see that people have been able to stop their leak without removing the IP.  

Dieselgeek has a very detailed four page instruction for pump head seal replacement for a TDI IP.  Although there are a number of difference between the two procedures the one major one has to do with the tightening of the center bolt.  I spoke with Jim at Dieselgeek.  He was uncertain if it was possible to do the AAZ IP on the engine as there are some small parts inside that are not there in the TDI IP.  I assume these are the reason for continuing to maintain tension on the center bolt.

If required I can reinstall the timing belt and use the gauge to reset the IP timing.  However, given that this is an engine out of Germany with unknown history I think if I am going to have to pull the pump off I probably will at a minimum send it for a complete reseal or just bite the bullet and buy a rebuilt one.

With regards to buying a rebuilt one I see prices from around $300 + core to $450 to $600 to $1200+ at the dealer.   The German VW price is around $590 euros.   Needless to say my wife is happier with the lower price rather than the higher one.  Do you have any experience with the various on-line vendors and have any you have found to be dependable as well as reasonable??

Thanks for your assistance and advice.

Sam
Tucson, AZ