MK2 IP Gasket issues

[85golf]

Hi all, I have an 85 Golf Diesel with 370k that I am wanting to get back going for our temperate AZ winters. It has no A/C and so it gets a little "vacation" in the hot months. 

It's been hard to start and losing prime so we've deduced the IP is leaking air into the system. Once it starts though, it runs well. Here's my problem... I think I have bought the wrong o-ring/pump head gasket, and I am having a devil of the time trying to find an real Bosch DGK 126 kit. Have called many listed on Bosch's website as service centers or fuel injection vendors and no one can/will order it for me.

Can you look at these pics and let me know if I have the right gasket? I bought just the o-ring, allegedly "genuine oem", off Autohausaz. No maker marks but the gasket is green. You can see it on its way to being installed on-car in the photos, the old o-ring is the black one (broken now) that I have laid next to the green one for reference. This isn't going to work, is it?

[libbydiesel]

That looks too big to me.  You can get actual Bosch seal kits from the seller angelofishes on eBay.  Just send him a message.  Great guy to deal with with good prices.

It looks like you didn't remove the center bolt from the distributor head and keep pressure on the plunger.  Because of that, it is a crap shoot whether or not the little shim at the bottom of the plunger has fallen out of place.  If it has, the internals of your pump will be reduced to a pile of shrapnel when you crank your engine over.

[85golf]

Thanks for the heads up Libbydiesel. Since the plunger is now in question, maybe this is a good time to get the full rebuild kit and do it? We haven't done one before but I'm looking at the DVD on ebay and, assuming that video is any good, I like to think we could achieve it if patient. Definitely do not want to brick the IP. Does that sound feasible or is it not worth attempting at home?

I'll message angelofishes... I have been watching ebay but no genuine Bosch kits from anyone. Angelofishes does have an offbrand kit available right now though.

[ORCoaster]

With the O Ring you have there I would say STOP, Pull the pump and rebuild.  Get the full kit and it will have the right ring in it.  Like Libby says there is a little tiny washer that rides on the end of the plunger and if it is off then this pump has to come apart to make it work.  I use plenty of Vaseline on that washer, the tiny springs in the head and never have had a problem lowering the head down onto the plunger and getting it back together. 

Just remember that when rebuilding the whole IP gets nose DOWN in a vise, not sideways as it is installed on the car.  Everything comes out of the top or back of the pump during the operation.  Otherwise you have internals going everywhere and you may not know where they go to put them back.  Plenty of good videos to watch to help with rebuild.  Set up the laptop next to the workbench and use it for reference.

Good Luck.  But yeah, wrong O Ring.  The black one is skinnier to a point because it was compressed but it isn't as big as the one you have going.

Keep us posted.

[sgnimj96]

       feasible?  Thanks to the internet and these guys in the forum, YES...    if you have a bench vice, some good tools,  and are good with tools (you do not want to damage any of the fasteners).   Have lots of gloves,  paper towels, patience, etc.   
  Test the pump by hand using the sprocket to make sure everything moves/rotates smoothly afterwards. 
Before installing on the engine I like to: with the pump in a vice,  mityvac clean fuel into pump or use a small funnel.    Then, connect fuel lines (with a in-line filter) to a small container of fuel.  I use a 1/2" variable speed drill with a socket to spin the pump and watch it prime itself...   connect 12v to the fuel stop solenoid and see the delivery valves spit (use a bag to catch the sprays).   You can move the throttle arm and watch the fuel spits increase/decrease.       If all that works you probably did it right.

 I got the video before starting

[jhax]

http://gnarlodious.com/Vanagon/Bosch_Pump/-Rebuild no need for a video, just MAKE SURE you mark all necessary areas via my thread on this forum.

[85golf]

Okay, we've got it apart and are taking plenty of time to inspect, clean, and lay out the components. I went ahead and got the $30 Bosch VE rebuild step by step video off of ebay, because I figure if it saves just one mistake it could easily pay for itself. I really wanted a genuine DGK 126 kit bit went ahead and bought the next best thing from Angelofishes on ebay, and it turned out to be the Flag (made in Germany) brand kit. I'm confident.

There is some damage to the housing and I wanted to put up some photos and see if anything is a dealbreaker. This car was running and this pump was working before, but want to be realistic if these are serious issues. We seem to have ridges, a divot, and a discolored spot in the main housing. Although the page jhax linked me to has those ridges as well so perhaps they are intended/acceptable.

I brought out a macro lens to take pics and it made every little bump and swirl jump right out! (Well when I could get it in focus)

Can you guys check them and let me know if anything is really bad?

[sgnimj96]

        The brass bushings in the front of the housing are wear items (usually from over-tightening the timing belt).    Worn bushings can cause the front seal to leak fuel out or suck air in at the shaft.       Most people don't like replacing those bushings, because it's a lot of work,  and just install the new seals in the kit.        If the brass bushings are ok,  and the rollers/camplate are not badly pitted - you're probably good to go.