Author Topic: 1.6 TDI, spewing fuel from top of the pump, help!!!! (Read 3999 times)

HeavyOiler · « **on:** September 01, 2008, 03:52:07 pm »

Hi there,
I have finally fitted the great 1.6tdi into my 89 Caddy, after a year of it sitting around. It was difficult to start, but I had it timed by a pro, diagnosed fuel delivery problems eventually (new filter, glow worms etc)
Opon start up, I discovered that its leaking badly from the
''part that the cable mounts to...on the top left of the pump...has two springs below it-before it enters the pump body....appears to be a plastic black outer seal/bush''
The throttle cable mount on the top has a single bolt holding it in from the top in the center, it appears to have play on this (sorry for the dumb description!!)
I dont want to dismantle it as the springs look complicated, and am worried that I will lose/mess up bits of the pump, so please feed me advice!!!
The engine is from a Golf GTD (mk2), and is the intercooled 80bhp version.
Its fitted with a Bosch pump, but I cant find any number on the body, but is different from the usual 1.6td pump (I have a spare td pump and was going to try and take the seal out, doubt its the same?)
Numbers I have found are 13B1301 by stop sol, 054 209 2 (or 3)54 B1 on the shaft end, none of which are correct, correct??
Cheers for any help, it has to be fixed asap, lost my storage space!
Andy

jtanguay · « **Reply #1 on:** September 01, 2008, 04:08:30 pm »

http://www.dieselvw.com/138ThrottleShaftBushing.htm

your better off just buying a new one and fitting it... but yes you want to scribe the orientation of pretty much all the pieces so that you can bring the pump back to the way it was running... and also don't forget to clean the pump really well... you do not want ANY dirt inside (sort of like working on a/c components)

it could also be a seal though...

HeavyOiler · « **Reply #2 on:** September 01, 2008, 06:10:16 pm »

Thanks,
Is this a difficult job, it looks easier than the other seals? Any special tools required? Dont particually want to take the pump off as its such a *** to put on or off.
A new pump is not an option (new engine cheaper by far), far to pricey, and its a decent engine besides this problem

Has anyone else had this problem.
Also would a conventional 1.6td pump (my non leaking spare) be easy swap, or would it not be work?
Andy

jtanguay · « **Reply #3 on:** September 01, 2008, 07:49:54 pm »

i think you could do it while the pump is on the car... but i've never done it myself. hopefully someone else who's done it will chime in

den052 · « **Reply #4 on:** September 08, 2008, 05:22:22 pm »

You can send your pump in on EBAY.com and for about $100 USA, they will reseal it for you. For $250, they will rebuild it.
Barring that, I stopped my pump from leaking (small leaks), by putting one gallon of E85 ethanol gasoline with the 9 gallons of diesel in the tank.
The ethanol swelled the rubber seals back to origional shape and stopped the leaks. It was amazing. As a diesel mechanic, I knew that ethanol would swell rubber slightly. The ultra low diesel fuel causes the old style rubber seals to shrink, and the pump then leaks. Newer seal kits solve the problem as they are made with different VITON rubber seals and etc. So far my VW is performing perfectly with no leaks. The ethanol had no harmful effects that I can see other than to stop the small leaks (awesome). I should post this on the forum as a possible fix for leaking injection pumps.

Smokey Eddy · « **Reply #5 on:** September 12, 2008, 03:14:13 am »

Do it. that sounds awesome. What a genius idea.

vern · « **Reply #6 on:** September 16, 2008, 12:26:50 pm »

I had this same problem on a 92 jetta.... I changed the top portion of my pump with a spare unit, and the top part is a *** to get off in the car, the back bolt was a pain, since it was a allen key with no room to work.

Once you get it off though, its just as easy as pounding out the brass piece, replace it and away you go. But I didnt actually do that much, just swapped with a good unit.