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changing IP shaft seal on 1999 TDI
by
paolomarks
on 20 Mar, 2014 08:51
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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.
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#1
by
TylerDurden
on 20 Mar, 2014 09:38
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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.
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#2
by
paolomarks
on 20 Mar, 2014 09:49
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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.
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#3
by
TylerDurden
on 20 Mar, 2014 09:59
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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.
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#4
by
paolomarks
on 20 Mar, 2014 19:29
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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.
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#5
by
burn_your_money
on 20 Mar, 2014 20:03
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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.
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#6
by
RobertMcC
on 22 Mar, 2014 09:16
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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.
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#7
by
CRSMP5
on 23 Mar, 2014 10:12
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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
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#8
by
paolomarks
on 10 Jun, 2014 22:05
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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.
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#9
by
Toby
on 10 Jun, 2014 23:33
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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.
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#10
by
vanbcguy
on 11 Jun, 2014 09:31
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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.
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#11
by
paolomarks
on 12 Jun, 2014 17:53
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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.
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#12
by
vanbcguy
on 12 Jun, 2014 19:47
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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
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#13
by
burn_your_money
on 21 Jun, 2014 07:39
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You can't use the IDI timing gauge on the TDI, the thread diameter is different.
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#14
by
libbydiesel
on 21 Jun, 2014 10:49
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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.