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Engine Specific Info and Questions => IDI Engine => Topic started by: Ziptar on May 01, 2010, 04:17:27 am

Title: Started my 1st IP Rebuild: Rusty Core? 3 Sided Bolt Tool? and Other questions.
Post by: Ziptar on May 01, 2010, 04:17:27 am

Ok, so it's finally my turn to try this ;) After much reading, re-reading, and agonizing  :o...

Last weekend I started tearing down a core IP to try my hand at a rebuild. I am glad I decided to get a core and not rebuild the pump that is on the car now so I could take my time and not stress. However,  The core has been sitting for a while and is full of rust.   :o  >:(  :(  :'(

(http://www.ziptar.com/bosch_ve_rebuild/ip_teardown.jpg)

(http://www.ziptar.com/bosch_ve_rebuild/ip_1.jpg)

(http://www.ziptar.com/bosch_ve_rebuild/ip_2.jpg)

(http://www.ziptar.com/bosch_ve_rebuild/ip_3.jpg)

• What is the best way to clean everything? Should I soak the parts in penetrating oil and use a old tooth brush or a rag to remove the rust? I am guessing using caustic parts cleaners, a wire brush, or other harsh methods are not a good idea for the pump internals.
• Even after I get everything clean i am still going to have pump internals that are going to be pitted. The pitting will causes the parts to wear much faster I would think so the life of this pump is going to be comparability short, yes?
• I've been scratching my head about coming up with a tool for two the three sided for the governor lever. Any Ideas on that? I saw a set of Irwin "rounded bolt extractors" at my local autozone last week. there is a 13mm and the shape looks like it could work but, the sockets only look to be able to loosen bolts.
  (http://www.uktools.com/images/js/big/IRBG.jpg)
• I need to order a throttle shaft bushing, the shop I ordered my seals from said there are a couple of different types and they'd need to the measurements from the old bushing, so now that I have it apart what do I measure?
• I need to replace the bushing used to connect the cold start lever to the cable. The reseal kit doesn't appear to have one, anyone know that part number?
• As long as I am this far into it, should I replace the IP shaft bushings as well, is that a bench top home job or are special tools required?

Thanks.... Wish me success!!

Title: Re: Started my 1st IP Rebuild: Rusty Core? 3 Sided Bolt Tool? and Other questions.
Post by: morgoon on May 01, 2010, 07:17:54 am

I really shouldn't be taken as a source of info, as I am on week two of being a Rabbit owner, but want to try this as well.

But the folks here are great and Vincent Waldon told me that a good source for a qualtiy rebuild kit is:
http://www.performancediesel.ca/...the (http://www.performancediesel.ca/...the) home of the Giles pump as I understand it, and don't forget the front seal..it is apparently almost as much as the rest of kit

•I've been scratching my head about coming up with a tool for two the three sided for the governor lever. Any Ideas on that?

I ordered this tool from prothe, not sure of the quality tho..it is still in the mail as of yet, but I think this is what you are talking about, but I could be wrong
(http://i1020.photobucket.com/albums/af324/morgoon/81%20Rabbit/BoschBoltAdapterSmall.jpg)
http://www.dieselvw.com/3SidedSpecialTool.htm (http://www.dieselvw.com/3SidedSpecialTool.htm)

Let me restate...I don't know jack, but this is what I have learned so far

Title: Re: Started my 1st IP Rebuild: Rusty Core? 3 Sided Bolt Tool? and Other questions.
Post by: starrd on May 01, 2010, 07:40:23 am

Best triangular socket is here: http://www.metalnerd.com/cat05.htm (http://www.metalnerd.com/cat05.htm)
Look at the bottom of the page: Part MN3001 - Specialty Socket for Triangular Head Bolts

Diesel is a good cleaner
 

Title: Re: Started my 1st IP Rebuild: Rusty Core? 3 Sided Bolt Tool? and Other questions.
Post by: burn_your_money on May 01, 2010, 08:09:21 am

Quote from: starrd on May 01, 2010, 07:40:23 am

Best triangular socket is here: http://www.metalnerd.com/cat05.htm (http://www.metalnerd.com/cat05.htm)
Look at the bottom of the page: Part MN3001 - Specialty Socket for Triangular Head Bolts

That is for the TDI pumps. It is way too small unfortunately.

If you give the shop your pump number they can look up what throttle shaft bushing you need. Otherwise press out your old one and measure the height (in mm) and let them know.

Bosch does not sell the bushings you are asking about. They are a VW part.

Your pump isn't too bad. Obviously getting some "new" parts in there would be ideal. How is the advance piston? Those guys usually get it the worst.