New Jetta Owner: Leaking Fuel Injector Pump

[Zu!]

Hello all:

Looking for some advice and peace of mind here  

I just bought this 91 Jetta Turbodiesel and everything was peachy pie for the first 2 weeks. Then I noticed my windscreen getting harder and harder to clean. Didn't think much of it, as it is winter after all and the roads are extremely mucky. Still...

Well, the other day, I noticed a puddle on the floor of my garage. Popped the hood and wow! The whole bonnet is like covered with oily stuff. Started the engine and looked under the thingamajig in the centre (where all the metal hose come out of) and noticed a fluid leaking out. Checked my Bentleys and it confirmed what I thought...the pump is leaking  

My mechanic says this can only be fixed by a specialist who rebuilds these things. He figures its the O-ring or gasket that's probably worn. This is looking expensive.

Any ideas?  :?

Thanks!

[be12clicks]

That would be your fuel pump, and yes it's likely the o ring or the gasket.  Although these wear with age, it has likely been most recently affected by the change in fuel in the past months, from LSD (Low Sulfer Diesel) to ULSD (Ultra Low Sulfur Diesel).  Since there is such a small amount of lubricity in the ULSD the rings tend to dry out when swtiched over. From my understanding this is rather common right now and equally common in the early 90's.  I've heard of people having the same issue when switching between D2 to BioDiesel.  The ring becomes conditioned to a certain sort of fuel and when it is drastically changed this results.  

Now, I have a 90 TD myself, I just got this car this summer, I noticed in the fall a minor leak and while in the process of looking for a pump to replace it (of which there are few) I started using the additive Diecyl, since that point I have not had any leaking coming from my pump, I've heard mention of the same thing on the TDIclub forums. Something to consider.  
When you got this car two weeks ago was it parked for awhile?  

In terms of the options you have, you could take it to a pump specialist, I called around, to do a full rebuild was around a grand after labor, just on the pump mind you, maybe you can find someone doing it cheaper.  Another possibity I was given was a patch method, basically they squirt some sealent in there and it holds for good, but the back pressure likely will build up elsewhere and you'll have to pay to have it done again elsewhere on the pump.  It's hard to say where the leak is without more information, but I've heard of plenty of people swapping out certain o-rings themselves, the kits are cheap and I figure if you have the time and patience it's not overly difficult.

[burn_your_money]

There is a guy on ebay that will put new seals in your pump for around $150 I think. I don't know who he is, or how good or a job he does. I'm sure if you read his feedback you could get some ideas.

Depending on what seal it is and your level of competence with the pump you might be able to do it yourself. There are several writeups on the site regarding it.

It might just be one of the steel lines though, which would be much easier

Take a good look at it and try and identify where it is coming from

[jtanguay]

you might just want to get your pump rebuilt by a diesel shop over in BC... should cost you around $450 at least, but will be worth it.  

If you like tinkering with stuff then you could try to do it yourself, but you might just get frustrated if you don't have much patience.

[Zu!]

Gosh thanks guys! You guys are awesome!

Jtanguay: I am just getting into tinkering with my car and I know when I'm way in over my head (like now) so I would much rather get my mechanic to pull the pump out for me, send it to a rebuilder and then put it in back for me. I understand (from him) that once the pump is pulled, the timing has to be redone once it goes back in, and I don't think I'm quite ready for that.

Do you know anyone in BC that does this (pump rebuilding)?

be12cliecks: I haven't done any kind of bio-diesel yet. Just running on regular Superstore diesel. I don't know if they did any kind of change in diesel over here in BC.  That additive (Diecyl) sounds interesting, at least until I have the money saved up for the rebuild. Could i find it at the local Canadian Tire? And you're right, when I bought the car, it was parked outside under 6 inches of snow. I scraped it all off, cranked the car and after considerable cranking, it started up. The car doesn't smoke at all once warmed up, and the only complaint I have about it is that it is really slow up the hills and off the lights.

The other day, I was on a set of lights right next to a bus. The bus beat me to the next set of lights (uphill to boot!)  :oops:

Apart from that, I just love the car!

burn_your_money: The leak only happens when the car is running. Then I can actually see the drip coming from somewhere underneath the pump. I don't think its any of the steel lines as those are all clean even at the junction.

Thanks for all the tips fellas!  

[be12clicks]

I haven't seen Diecyl in Canadian Tire yet, it is a germen product and the bottle actually doesn't have any english on it.  Although I know it is being imported in quantity because it comes with an english sticker over part of it with instructions.  I buy it from my mechanic, he gets it from his supplier.  



http://www.tdiparts.com/catalog/product_info.php?products_id=543

[commuter boy]

There's a few good shops in BC that do rebuilds, though I found shopping around last year that Giles at Superior Fuel Injection in Ontario would do a performance rebuild for only a small amount of money more, even after shipping.  

Where are you located and I'll try and point you to someone local.

[Zu!]

Hi Commuter Boy, I'm located in the Lower Mainland in the Pitt Meadows / Maple Ridge area. Thanks!

[commuter boy]

NW Fuel Injection across the river in Port Kells then, or Jim's Fuel Injection down off Marine drive near the Knight St. Bridge.

[Zu!]

Thanks CB. I sent out an email to Giles as well, with a few questions, but he has yet to get back to me. I'll let everyone here know how it goes...when it goes  :?

I reckon I've lost about 60 kms of distance already. Hard to tell as this was only my 2nd fillup, but the first tank went 760 and this one's gone 700, so... I also sent an email to nw. They've got a website http://www.nwfuel.ca/about.htm that actually shows a pump that looks exactly like mine! Lets see what they say. Another one I sent an email to was an outfit in Langley called Dynamic Fuel http://www.bannertown.com/dynamicfuel.htm

My mechanic has also been busy trying to source out people who do this kind of work. Either way, I'm going to have to get this fixed and my pocket nicely burnt  :cry:

[Doug]

Has anyone had any first hand experience with replacing seals to stop a leak from the throttle shaft on the IP? Mine is leaking and would like to hear from another tinkerer.

[alka1ine]

I've just recently saw my pump leaking from the throttle shaft too...

I think it started to after all the cranking and pumping of the gas i had to do in this cold weather.  I just need a block heater because i think it's just not cranking fast enough.

[bvolks73]

Mine is leaking from the throttle shaft too. Is that an easy fix? I've been calling around looking for some seals for mine locally and am not having much luck, not even the dealer has them.

[BlackTieTD]

hey zu. try cleaning up the area where the leak is coming from. once you have it clean, hit it with some brake clean to dry it right out. then start the car and watch. identifying where exactly the leak is originating from will often help you save time/money in the long run. could just be a line as burn says... but probably not. at least if you know what seal is leaking you can research doing the job yourself... at the very least you will be knowledgeable enough that if you have a shop do it, they won't dick you around because you'll know whats up. good luck.

[BlackTieTD]

ps - try to get your mechanic to let you watch the pump re-install and timing procedure. then you will know for next time.

i was going to suggest getting a cheap pump from a junkyard car and throwing it on just to see what happens (maybe it ends up being in good shape??) but that is not worth the labour if your mechanic is doing it.

alternatively you could get another pump from a junkyard car and send that one out from rebuild if there will be a delay getting it back... then you can at least keep driving the car in its current state. buy a fire extinguisher?