New Pump Appears to have Stopped Pumping Fuel

[Smokey Eddy]

Sorry if this seems out of context but im seconding something i think rabbit on roids said about the shaft seal on the pump not being pressed fully (or is damaged on install)
That is a very logical place for the pump to suck air from ...

ps. I didn't mean to point the finger at your Giles, it was merely a suggestion but i know you don't think i was. I just wanted to clarify that in black and white. IF i had the money, as i've said to you before , i'd pay you to do me up a wicked pump with a huge pump head and properly calibrated, non-leaking injectors. Siighhhh maybe one day ...

[burn_your_money]

Here is the link. It is 159.99

http://www.samstagsales.com/vwaudi.htm#axle

Search for "VW210" and you will find it.

I have never dealt with these guys but got their link from a vendor on vortex that said they get almost all their specialty tools from there.

[veedubcanuck]

Or a cheaper version...

http://cgi.ebay.ca/ws/eBayISAPI.dll?ViewItem&item=400094272995&ssPageName=STRK:MEWNX:IT

[Doakster]

Yup, I ordered the one off ebay, $50 bucks shipped, and it seems like a decent tool, made of all steel, while the VAG210 looked like it was part plastic.

[Giles@PerformanceDiesel]

Hi Andy
back home now, in Keswick, ON, Canada
reading about your sucking air pump is getting allot of attention, thanks very much for all the great suggestions guys.
the belt tension thing to me sounds about the best option right now. too tight will very quickly ruin the brass drive shaft
bushings and beyon the Bosch limit of .25mm drive shaft play. we replace the bushings if it's even close to .2mm to give
max life to the new owner of their pump.

take the belt off the pump pulley and measure the side to side play of the shaft at the base if you can.
i am not saying we can't make a mistake installing the shaft seal but it's highly unlikely. the seal is the first thing to go into
the housing before the drive shaft even, then the drive shaft very carefully with oil on it.
i have called andy and am waiting for him to call back now.
one other thing, a pump can seem like it's making air when you rev it up because there is allot of air trapped in the advance
piston gaps during a fresh install and it takes allong time to clear this and it won't unless you rev the motor up. so don't give
up just because you see air. keep doing it.

Giles

[Rabbit on Roids]

there was still fresh diesel under the timing belt cover, he said it was coming from the seal.

[Doakster]

Little update, talked to Giles today, thanks for all the support and help.

Basically I'm going to measure the end play in the pump shaft and see what it comes up to. I probably won't get to it for a few days, and I have to see if my work will let me borrow the dial indicator with the magnetic base.

Long story short, my hunch is there is going to be some excessive play in the pump shaft, meaning bushing is toast.

[Doakster]

Ahhh....screw it, i just ordered a cheap mag base and dial indicator off Amazon, probably take a week or more to get here, i could use one anyway.

In the mean time, i'll pull the timing belt off and check for play by hand, or maybe rig something up with my set of calipers to measure the end play.

[Giles@PerformanceDiesel]

techcically it's side to side play not end play, when you check it make sure it's at about 35-40 deg below horizontal on the shaft
on left side of drive shaft looking at it straight on. this is the same angle as the belt pulls down and to the left.
Giles

[Doakster]

techcically it's side to side play not end play, when you check it make sure it's at about 35-40 deg below horizontal on the shaft
on left side of drive shaft looking at it straight on. this is the same angle as the belt pulls down and to the left.
Giles

Gotcha, i said end play, but knew you meant side to side play when we talked.

Do you always measure with the pump pulley removed? Or would there be any benefit to keeping the pump pulley on when measuring. Seems like you should get the same measurement regardless.

[rabbitman]

techcically it's side to side play not end play, when you check it make sure it's at about 35-40 deg below horizontal on the shaft
on left side of drive shaft looking at it straight on. this is the same angle as the belt pulls down and to the left.
Giles

Gotcha, i said end play, but knew you meant side to side play when we talked.

Do you always measure with the pump pulley removed? Or would there be any benefit to keeping the pump pulley on when measuring. Seems like you should get the same measurement regardless.

The pulley will give you something to push on provided you can get the tool behind it.......

[Doakster]

Finally had a chance to pull the IP pulley off and take a look at the pump today, this is what i found with the pulley off, pretty obvious the pump seal is leaking.




Since i haven't received my mag base and dial indicator yet, i checked the side play by hand, here is a shot of the pump looking straight at the shaft.




And here is a pic with a little side pressure on the shaft, pretty obvious there is excessive play, i figure it is around 3mm or more, also fuel POURED out of the seal very badly when doing this. Going to send the pump back to Giles.



It's pretty obvious the timing belt tension must have been the problem, I just can't win with this car. I'm sure Giles will straighten things out. Giles if you are reading I sent you and email with a few other detail, I'll touch base with you soon.

[rabbitman]

Crazy......the belt would've had to be waaaay too tight to wear it that fast, I thought I read somewhere that a t-belt that much over tightened will just break? Or at least whine really loud.

Too bad though

[Doakster]

Crazy......the belt would've had to be waaaay too tight to wear it that fast, I thought I read somewhere that a t-belt that much over tightened will just break? Or at least whine really loud.

Too bad though

Yeah, kind of a sucky situation. All I can say is that it was tightened to the 45 degrees twist test, and I could go a little further.

Pretty frustrating, but it will get fixed.

[rabbitman]

One thing I've discovered is the belt isn't supposed to "stretch" during the twisting, it's supposed to just be taking the slop out of it.

I usually measure the slop just by yanking the belt up and down between the pump and cam, IIRC it should go almost an inch from top to bottom to take the slop out.