NOLA Speed and Style

Author Topic: changing IP shaft seal on 1999 TDI  (Read 3419 times)

March 20, 2014, 08:51:57 am

paolomarks

  • Junior

  • Offline
  • **

  • 146
    • View Profile
changing IP shaft seal on 1999 TDI
« on: March 20, 2014, 08:51:57 am »
My friend has a 99 jetta TDI manual tranny.  IP has been leaking and I've told her I'd help her with it.
I've re sealed a 1.6na pump and an AAZ pump successfully while they were out of the vehicle, but have never done a TDI. Which seals can I replace while it's in the car?  Hard to see which seal is leaking(pump is filthy)  The pump leaks enough that if you let the car sit for a few days it needs to be primed in order to start.  Does this suggest a certain seal?  Thanks in advance,  Paolo.



Reply #1March 20, 2014, 09:38:33 am

TylerDurden

  • Veteran

  • Offline
  • ***

  • 1508
  • Personal Text
    I have a VW problem.
    • View Profile
Re: changing IP shaft seal on 1999 TDI
« Reply #1 on: March 20, 2014, 09:38:33 am »
I'd put a clear lines on the IP and see where the air is getting in.

I'd also check the tee-fitting on the fuel filter. It can let in air when the car sits and fuel will siphon out of the IP.

Reply #2March 20, 2014, 09:49:26 am

paolomarks

  • Junior

  • Offline
  • **

  • 146
    • View Profile
Re: changing IP shaft seal on 1999 TDI
« Reply #2 on: March 20, 2014, 09:49:26 am »
Thanks for the reply.  A problem with the T fitting would siphon fuel out the IP back to the tank? It would not leak fuel out the seals of the pump, right? 
   Will I be able to replace the IP shaft seal and top gasket with out a Vag com?  Thanks, Paolo.

Reply #3March 20, 2014, 09:59:06 am

TylerDurden

  • Veteran

  • Offline
  • ***

  • 1508
  • Personal Text
    I have a VW problem.
    • View Profile
Re: changing IP shaft seal on 1999 TDI
« Reply #3 on: March 20, 2014, 09:59:06 am »
When either line has a leak, air pressure and gravity pulls the fuel toward the tank in both lines, when the engine is off.

Even if the leak is in the return line, if the car sits long enough the supply line will siphon out the IP.

Reply #4March 20, 2014, 07:29:00 pm

paolomarks

  • Junior

  • Offline
  • **

  • 146
    • View Profile
Re: changing IP shaft seal on 1999 TDI
« Reply #4 on: March 20, 2014, 07:29:00 pm »
Assuming the return and feed lines are fine, is it indeed possible for a pump to lose prime over a couple of days just from leaky seals?  If so , which seals might be the most likely culprits, and can they be replaced in-car and without afterwards needing a vag-com to recalibrate the pump.  Thanks, Paolo.

Reply #5March 20, 2014, 08:03:30 pm

burn_your_money

  • Global Moderator
  • Veteran

  • Offline
  • ****

  • 9007
  • Personal Text
    Bright, On
    • View Profile
Re: changing IP shaft seal on 1999 TDI
« Reply #5 on: March 20, 2014, 08:03:30 pm »
Wash the pump and then drive it and look for leaks.

You can replace the very top cover without VAGCOM. You can actually do all the seals except for the one below the top cover, where the top (actuator) sits on the pump body. Do not try and take out the 4 small torx? screws on the electrical connector on the pump. That seal is not serviceable.
Tyler

Reply #6March 22, 2014, 09:16:39 am

RobertMcC

  • User+

  • Offline
  • *

  • 28
    • View Profile
Re: changing IP shaft seal on 1999 TDI
« Reply #6 on: March 22, 2014, 09:16:39 am »
The top plate seal you can change easy, but you need a special tool to remove a triangle bolt. Theres DIY for TDI pump on youtube changing the seals w/o removing the injection pump. Bosch kits are only like 12$ and comes with all the serviceable seals and crush washers.
2001 Jetta TDI ( 216, CX racing FMIC )

Reply #7March 23, 2014, 10:12:09 am

CRSMP5

  • Guest
Re: changing IP shaft seal on 1999 TDI
« Reply #7 on: March 23, 2014, 10:12:09 am »
If the black electrical box is leaking u screwed, pump at that moment as no one has them, ive looked high low with no success, so go look now...

What car, engine?? Ill be pulling good mk3 pump off jetta today thats getting a rover pump... Im in athens ohio this week at vw shop specializing in diesels, so close to wv too, i know it will be 4sale

Reply #8June 10, 2014, 10:05:50 pm

paolomarks

  • Junior

  • Offline
  • **

  • 146
    • View Profile
Re: changing IP shaft seal on 1999 TDI
« Reply #8 on: June 10, 2014, 10:05:50 pm »
  So we're still trying to figure out the problem with my friends 99.5 Jetta TDI(AHU) We put a vacuum fuel extractor on the IP return and a steady foam of bubbles comes out.  The IP intake hose has no bubbles.  I took off the timing belt cover and it seems pretty dry in there(Shaft seal OK?)    Is there anywhere else to do or check before replacing IP cover seal and actuator seal?   After drawing fuel(and bubbles)  through the IP we cranked it over while I bled air out of the steel lines at the injectors.  Engine sounds like it wants to start but wont.    Thanks in advance, Paolo.

Reply #9June 10, 2014, 11:33:23 pm

Toby

  • Veteran

  • Offline
  • ***

  • 728
    • View Profile
Re: changing IP shaft seal on 1999 TDI
« Reply #9 on: June 10, 2014, 11:33:23 pm »
Pull the pump and reseal everything. I chased problem with losing prime and very poor hot restarts for 3 months until I jerked the pump and resealed everything. I never did figure out where it was leaking air. Never leaked a drop of fuel, but it would not hold vacuum. I replaced all of the seals that you can get with the pump in the car, to no avail. After the complete reseal, no problems.

Reply #10June 11, 2014, 09:31:58 am

vanbcguy

  • Administrator
  • Veteran

  • Offline
  • *****

  • 2831
  • Personal Text
    Vancouver, BC
    • View Profile
Re: changing IP shaft seal on 1999 TDI
« Reply #10 on: June 11, 2014, 09:31:58 am »
The shaft seal is under vacuum when the pump is running as it is covering the vane pump.  If it has a small leak it often will let air in to the pump without leaking any fuel out. 
Bryn

1994 Jetta - AHU M-TDI - Jezebel Jetta
2004 Jetta Wagon - 1.8T - Blitzen

Reply #11June 12, 2014, 05:53:24 pm

paolomarks

  • Junior

  • Offline
  • **

  • 146
    • View Profile
Re: changing IP shaft seal on 1999 TDI
« Reply #11 on: June 12, 2014, 05:53:24 pm »
OK, so it seems like the problem is with the pump letting in air.  I don't have a Vag com, If I pull the pump and reseal everything will I be able to time it afterwards.  I have the dial indicator for the IDI engines.  Thanks,  Paolo.

Reply #12June 12, 2014, 07:47:20 pm

vanbcguy

  • Administrator
  • Veteran

  • Offline
  • *****

  • 2831
  • Personal Text
    Vancouver, BC
    • View Profile
Re:
« Reply #12 on: June 12, 2014, 07:47:20 pm »
If you've got the dial indicator you'll probably be OK. Measure it before removing the pump and set it back exactly the same. The computer will take care of small adjustments on its own.

Sent from my HTC One XL using Tapatalk

Bryn

1994 Jetta - AHU M-TDI - Jezebel Jetta
2004 Jetta Wagon - 1.8T - Blitzen

Reply #13June 21, 2014, 07:39:56 am

burn_your_money

  • Global Moderator
  • Veteran

  • Offline
  • ****

  • 9007
  • Personal Text
    Bright, On
    • View Profile
Re: changing IP shaft seal on 1999 TDI
« Reply #13 on: June 21, 2014, 07:39:56 am »
You can't use the IDI timing gauge on the TDI, the thread diameter is different.
Tyler

Reply #14June 21, 2014, 10:49:01 am

libbydiesel

  • Veteran

  • Offline
  • ***

  • 2972
    • View Profile
Re: changing IP shaft seal on 1999 TDI
« Reply #14 on: June 21, 2014, 10:49:01 am »
The thread diameter is the same, but the timing plug has a tapered cone end to it and the large triangle nut has a smaller diameter hole.  You can swap on one of the large triangular nuts from an IDI pump and the timing gauge will work fine.
Use, abuse or ignorance of any information is at your own risk, confirmation or refutation is your own responsibility, no further 'proof' will be given, take it or leave it, YMMV,terms subject to change without notice, avoid contact with eyes or skin, contents known to cause cancer in California

 

NOLA Speed and Style