Injection Pump Problems - please help

[MikeyB]

I have a 1982 Diesel Westy. It was originally a 1.6NA motor. Recently I purchased (from Z & Z Imports) and had installed a 1.9 turbo diesel, model ABL.

After consulting with several diesel experts, I decided to use the 1.6 injection pump. I had the pump completely rebuilt. The mechanic who installed the motor initially tightened the belt too tight and the seal on the injection pump was damaged. The pump began to leak fuel all over the place, so I had the seal on the pump replaced. The mechanic who replaced the seal is the same guy who rebuilt the pump. He said there was some play in the shaft, but not too much. It worked well for a day, but within 24 hours, the leak came back as bad as before.

Here is my question: Is it possible that the 1.9 simply has too much power for the 1.6 pump and, therefore, when I step on the gas, the tension on the belt pulls the drive shaft in the pump, causing it to damage the seal? Should I switch to the 1.9 TD pump? Can anyone give me some insight on this issue?

Thanks guys,
Mike

[dillenger1]

Its definetly not to much power as the pump internals are very similar.

[AudiVWguy]

The mechanic who tightened the belt is the guy you need to talk to. He should take responsibility for his actions.
-JB

[rallydiesel]

The pump will continue to leak until the shaft bushings in the pump body are replaced. The guy who originally over-tightened the timing belt caused the bushings to wear on one side causing the shaft play. The "power" of the 1.9 has nothing to do with the bushing wear. I don't see any reason why you couldn't use a properly tuned 1.6 pump on a 1.9 engine and get near stock perfomance.

[jackbombay]

The pump will continue to leak until the shaft bushings in the pump body are replaced. The guy who originally over-tightened the timing belt caused the bushings to wear on one side causing the shaft play.

Yep.

The mechanic who tightened the belt is the guy you need to talk to. He should take responsibility for his actions.
-JB

  Eggsackly.

[Quantum TD]

The pump will continue to leak until the shaft bushings in the pump body are replaced. The guy who originally over-tightened the timing belt caused the bushings to wear on one side causing the shaft play.

Yep.

The mechanic who tightened the belt is the guy you need to talk to. He should take responsibility for his actions.
-JB

  Eggsackly.

Yeah. Sounds like you'll need to have your pump rebuilt again, in which case the mechanic who overtightened the belt should pay for the replacement parts for the pump. If he puts up a fuss, just remind him that he COULD be buying you a whole new motor. An overtightened belt can lead to loss of oil pressure, and blown rods. If he still complains, sue him for the $500-800 to rebuild/replace the pump.

[dillenger1]

The 1.9 lines are longer because the 1.9 is a little taller then the 1.6.The high pressure  head assembly is shorter as well i think,so lines are longer that way to.

[Smokey Eddy]

I haven't read all the replies in detail but i do not think a motor would have too much "power" for something driven off the belt. Sounds to me like having the belt so tight fuxxord the shaft bushings or the shaft it's self. I would not blame the engine.