leaking injection pump

[TDSami]

hi all my 1.6 leaks at the rear of the pump where the lines to the injectors go into that block, my question is do i have to remove the pump or can i sneak it out far enough to change the 0ring without dropping and vitals out of place or will i have to remove and stand on end and use vasaline or something to hold all in place to reassemble? thanks

[jimfoo]

You can do it in place by using a long bolt in place of the middle bolt, so that you can keep pressure on the plunger, holding the rollers in place. The procedure is something like slowly unscrew the 4 bolts holding the head on while slowly screwing in the center bolt. Do that until you have access to the o-ring, then remove 1 outer bolt, cut and remove the old o-ring and put the new o-ring on beneath the hole, then replace the bolt. Repeat with the other 3, then slowly unscrew the center bolt while tightening the outer bolts until everything is back together. Make sure to lube the new o-ring also. There is a thread somewhere on here about the procedure.

[burn_your_money]

I would not recommend doing it on the car. There are more pieces (springs) that will/may fall out plus the rotor is extremly high percision. You aren't even suppose to touch it with your hands.

Take the pump off at the very least.

Or, fill the pump with ATF, let it sit for 24 hours and it should fix the leak. It only lasts for a few thousand KMs before it fails again though so start saving for a super pump

[jtanguay]

i think libbybapa said that you can possibly stretch that seal around the pump head?  sure beats taking the pump off!

but do try the ATF trick first to see if that works  ATF stop leak swells seals up too so you might want to add some, although not sure whether it would harm a pump or not...

[suomistyler]

many truckers swear by the ATF method of lubing their diesel pumps....i've occasionally done so too when changing the fuel filter by filling it with ATF. You can also add a little amount to every fillup of diesel. My pump went over 500,000 kms before it started leaking. Problem is that the ULSD fuel shrinks the old seals and if you have one seal leaking, its highly likely that the others are not far behind. Changing one seal yourself will probably be a shortterm solution until another one of the seals starts to leak. If you are going to drive your car for the longhaul, i recommend getting the pump resealed instead to save you the heartache. if the pump works fine otherwise, don't get suckered into a rebuild and reseal that can cost from 1200-1700 dollars here in BC...

I just resealed mine through a guy on ebay (red--rider) and he only charged 115 bucks plus shipping and customs fees. With the labour it took to pull the pump and reinstall at my local vw mechanic, it ended up running me under 600 dollars. If you are handy enough to remove and install it yourself, the cost will be around 200-250 at the end of the day..not bad for a fully resealed pump that's guaranteed leak free for a year.


The only downside is having your car sit while you send it off to North Carolina and wait for it to come back...it took me about 2.5 weeks to get my car back on the road but the money i saved made it worth it.

http://cgi.ebay.ca/ws/eBayISAPI.dll?ViewItem&item=250278312911&ssPageName=MERC_VIC_RCRX_Pr2_PcY_BIN_IT&refitem=250274375643&itemcount=2&refwidgetloc=closed_view_item&usedrule1=CrossSell_LogicX&refwidgettype=cross_promot_widget&_trksid=p284.m183&_trkparms=algo%3DCRX%26its%3DS%252BI%26itu%3DUCI%252BSI%26otn%3D2

[Ziptar]

It can be done while it is on the car, just be careful and use the bolt, You can get a 80x1x40MM fine thread bolt at NAPA for $0.89.

I did mine while I was swapping the engine, engine was installed but, I hadn't put the radiator, core support, etc back on so I had lots of room to access it. I had also pressure washed everything while swapping so it was very clean.

If you do it on the car, CLEAN THE AREA WELL!!

Thread here about how to do it using the bolt method.

I did eventually have to pull the pump as the o ring for the cold start lever was leaking as well.