That is correct. An keeping things clean is also very important! The way I kept pressure on the main plunger was by backing the four T-30 torx bolts out just enough to expose the o-ring, then remove only one at a time to slip the o-ring over each T-30. That means at any given time there's always 3 T-30 in place.
THAT IS NOT GOOD ENOUGH. YOU GOT VERY, VERY, VERY LUCKY THAT YOU DIDN'T DESTROY YOUR PUMP!!![/size]
There is a very small washer at the base of the main plunger that is all of 1/16" thick. If you do not maintain pressure ON THE PLUNGER (my method is to add a small spacer under the timing plug bolt and tightening that bolt down on the spacer and plunger as I loosen the four mounting bolt for the head) then loosening the distributor head far enough to remove the o-ring will definitely allow plenty of space for that little washer to fall out of position. If it falls out of position, your plunger will be torqued sideways and WILL break the first time you turn over your engine. The pieces of shrapnel accumulate very quickly from there on out. YOU ARE VERY, VERY LUCKY THAT DIDN'T HAPPEN TO YOU!!!
I am hoping that I am emphasizing this all enough that anyone hoping to do the same makes sure to take the RIGHT PRECAUTIONS to ensure that their pump doesn't become TRASH.
For anyone considering doing the above mentioned procedure DO NOT DO IT THE WAY IT HAS BEEN OUTLINED BY 92EcoDiesel Jetta!!! YOUR PUMP WILL MOST LIKELY BE GARBAGE AFTERWARD IF YOU DO!!
[92EcoDiesel Jetta, I appreciate your input and am very glad that your procedure worked for you. I am not in any way attempting to belittle you or your contribution to this forum. I am only trying to save others some heartache. Everyone else I know of that has done it that way (I know of several) has ended up with a destroyed pump.]
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I guess I am lucky. I must say the head, which was backed out by not more than 3/8" at most, felt like it was always being pushed against by a spring and not just floating. I don't understand the spacer you speak of. If you put a spacer under the timing plug bolt, wouldn't that move the bolt further away from the washer and plunger? Am I reading it wrong? Seems like you need a longer bolt to maintain more pressure? Please clarify.
This is not my procedure and I found it online somewhere. It never mentioned about adding a spacer. I can dig it up and post a link to it later.
ps. libbybapa , no belittling felt. I was merely documenting what I did- good or bad. I was ready for the possible consequences of failure and did my best to work clean and slow and I lucked out.
Here's one of the procedure I used, even though it was not for my 92 model year:
http://www.dieselgeek.com/TDI_Injection_Pump_Head_Seal_Replacement.htmHere's another that I looked at:
http://cgi.ebay.com/ebaymotors/VW-Diesel-Injection-Pump-Gasket-Kit-Rabbit-VITON-BIO_W0QQitemZ150348086849QQcmdZViewItemQQptZMotors_Car_Truck_Parts_Accessories?hash=item230171be41&_trksid=p3911.c0.m14&_trkparms=72%3A1205%7C66%3A2%7C65%3A12%7C39%3A1%7C240%3A1318