What is the secret to resealing the pump cover?

[Turbofan]

Today I got out of work and decided to Gov. mod my 1.6 beast. (Yay!) But I can't seem to get me new gasket into the recess of the pump cover (boo!). Is there a trick? It seems the "ribs" on the new gasket are too fat to sit in the cover. I'm really scratching my head on this. The gasket kit I have is a Bosch DGK126, and everything I've found says it should be correct.

Save me Obi-wan, before I decide to reuse my old gasket and regret it.

Thanks a thousand. Or more.

[burn_your_money]

Carefully cut the ribs off the gasket. You have the wrong one. If you bought it from a local shop ask if you can trade it in.

[Turbofan]

Figures. Thanks.

[flowmastergfunk]

I'll be damned! I was able to gently smuggle all of the ribs into the grove with my pocket screw driver. I thought it was a pain but it certainly helped hold the gasket in place.

[burn_your_money]

Early pumps used one style, later pumps the seal with the ribs. The later seal is much better although still a bit tricky to get into the groove. I don't think it is possible to get the later seal in the early cover. I could be wrong as I never tried. It's also been a few years now...

[Turbofan]

Dropped into the diesel shop on my way in to work today. I ended up using a screw driver to gently persuade the seal in, but I didn't like the results. I guess in this kit there are two different pump cover seals, one that looks like it would fit but doesn't, and one that you wouldn't think is a pump cover seal because it's circular and not in the shape of the recess.
As it turns out, the shaped one that doesn't fit is meant for the Cummins pump, while the circular one is for the VW one. At least I don't have to put the cover on yet.
Hope this helps someone in the future!

[libbydiesel]

The circular one will work but is very easy to tear or pinch during assembly.  The fitted one with the nubs works fantastically if you remove the nubs with a fresh utility blade.

[fatmobile]

I used to snip the nubs off.
 it fit tight in the groove.
 So tight that after I bolted it down it broke the thin aluminum lip surrounding it.

 Now I cut them with a razor blade; even with the rest of the seal..

[Turbofan]

I did the same. I cut the ribs flush and used that gasket since I liked the fit better than the circular one. It's definitely the way to go.

[damac]

i have been using the circular one since the bosch guy i get my parts from told me to.  never had a leak and everything seals fine.  this is just turbo pumps, i haven't resealed a na pump yet.

[libbydiesel]

Of many resealed pumps I have had three times that the circular seal failed.  All were my own doing.  Once it slipped and got pinched, twice it got marred on the alignment pin.  I have not had any situations where the fitted seal failed when the nubs were removed.  It is easier to use and IMO works better provided the nubs are removed properly.  Because the seal kits come with both I keep the other as a spare regardless.

[R.O.R-2.0]

apparently all my pumps are LATER pumps, ive never had to remove the tits from the seal..

it fits pretty tight in the groove, but not alarmingly tight..

had to use the round seal on grandpas pump..

[EcoTX]

I've used the round seal (no nubs) on every pump I've rebuilt, early and late.