Hi,
I was helping a friend work on his '90 Jetta 1.6D today. The car leaks diesel from the bottom of the injection pump - a fast drip. We removed the injection pump and replaced the cold start seals but after it was reassembled, the pump was still leaking! It seems to be coming from right around the shaft itself.
Should diesel fuel be present in the area of the large piston at the cold start shaft? In other words, is there some other seal on the piston that we can't get to without opening up the pump, and are the O-rings we replaced not designed to seal that area from fuel? We just replaced one small O-ring on the shaft and two larger O-rings under the cover plates on each side of the pump.
Hopefully it will be something obvious, but if it turns out there is some other more serious problem, does anyone have a used or rebuilt pump that will fit a '90 Jetta that they would part with?
Thanks,
-David
This sounds just like the IP leak I had with my 90 Jetta. It turned out to be the end seal around the main shaft. Be prudent when you replace the injector pump and go ahead and replace the timing belt and adjuster. Diesel fuel can reduce a timing belt to a "puddle of goo" in a hurry.
I would recommend getting the IP rebuilt. Especially if you have one with the altitude compensator like I had.
The governor comes in much earlier in the rebuild that I purchased.
Good luck