injection pump top cover seal replacement

[92EcoDiesel Jetta]

I am getting ready to replace a leaky top cover seal and want to check in here with those who have done it before. It looks like I have to remove the throttle springs and shaft to get the cover off. Is there anything else I have to remove and be careful of?

[ilikevwdiesel]

I pm'd you

[R.O.R-2.0]

its very straight forward, be sure to mark the accelerator levers position to the throttle shaft..

and be careful with the springs, hold both hands over those things when you pop them off, they like to go flying.

there are 4 bolts holding the top to the pump. i believe you have to remove the idle adjustment screw to get at one bolt.

then of course the return lines, and that sort of thing, then push the throttle shaft down, or out of the pump top. i just push it down in the bore far enough to reach up in the pump and disconnect the governor linkage..

[ilikevwdiesel]

http://www.vwdiesel.net/forum/index.php?topic=4353.0

[92EcoDiesel Jetta]

Thanks for the input so far.

This pic is from July 2011 when I replaced the advance piston cover seals. I did not replace the top cover seal since it was not leaking back then (should have in hindsight). Anyway, my question is will the piece under the asterisks prevent the cover from coming off? This piece is on the backside of the pump (facing the block) and the nut on the right is attached to the top cover. I'd like to do the top seal without removing the IP if possible.

[R.O.R-2.0]

quite easy to do the top seal with the pump on the car..

[92EcoDiesel Jetta]

There is a small spring attached to that lever, but it's easy to detach/attach.

So I do not have to undo the nut on that lever, just unhook the spring to it then the cover should come off?

[rabbitman]

There is a small spring attached to that lever, but it's easy to detach/attach.

So I do not have to undo the nut on that lever, just unhook the spring to it then the cover should come off?

The spring is under the cover so you'll have to lift the cover partway and then undo the spring. It'll also make things easier if you loosen the fuel screw until you can see the o-ring.

Also to avoid getting diesel all over the hoses you can take a syringe and suck as much fuel as possible out the "out" bolt hole. It'll still leak some so have a rag handy. After you do it once it's pretty easy.

[92EcoDiesel Jetta]

http://www.vwdiesel.net/forum/index.php?topic=4353.0

Scott, it was good talking to you. Here's a pic of my pump with the throttle springs removed. Notice the black plastic cover and the length of the throttle shaft and also the bronze bushing on mine. Compared to the one in the tutorial link, mine is different (his does not have the plastic cover, does not have the bronze bushing and the throttle shaft is shorter)

[ilikevwdiesel]

by the looks of it you're going to have to get that plastic spring base off there before you can get that allen head bolt out, keep at it.

[92EcoDiesel Jetta]

OK new cover seal as well as a new throttle shaft o-ring is in, everthing is back together and leak is fixed!  I was very careful not to get dirt in the pump by cleaning before disassembly and assembly. I used a syringe on a 1/8 o.d. nylon line down the IP out bolt pedestal and was able to suck the IP dry so not a drop of diesel leaked out when the cover was removed. I took a few pics along the way which I'll post later.

[ilikevwdiesel]

http://www.youtube.com/watch?v=b-XhyLqC344&feature=related

[92EcoDiesel Jetta]

http://www.youtube.com/watch?v=b-XhyLqC344&feature=related

Nice! hehehe
Engine is running great! Nice and dry hehehe 

[92EcoDiesel Jetta]

The old seal was stuck to the pump, which was good at keeping dirt out of the pump when I scraped around it.

[92EcoDiesel Jetta]

There is a small spring attached to that lever, but it's easy to detach/attach.

Is this the spring you were referring to?


Having never been inside the top cover, I was referring to the external spring on the rod that is attached to the lever on the pump cover.