leaky injection pump

[davenclaire]

Its Gears mate, think there should be an access plate over the pump gear, but not sure, will look tomorrow if I remember, Rick

well if it all goes wrong tonorrow il have to remove the punp anyways lol

 

[geoffdown]

you could be right rick rad and ps pump are the only things left on but i didnt fancy pulling the timeing chain off will see tomorrow if it was the right thing todo.

Rad can stay no no chain its gears if engine move s its ok as there are. Z on the gears to time it up but u must mark the pump casing to the rear of the timing cover that way u wont need a dti gauge the only thing u will need to take off that u haven't mentioned is vac pump which if its not on the back of the altantor its under the ip:thumbs

 

[geoffdown]

Its Gears mate, think there should be an access plate over the pump gear, but not sure, will look tomorrow if I remember, Rick

Yes cover and under neath is the pump sprocket which will need taken off:thumbs

 

[davenclaire]

i am glad to report success :clap:clap:clap no more leaking IP i had a sleepless night wondering if my surgery to the distributor head would result in internal kerplosion of the pump but as i suspected playing with the old nackerd one i had nothing came loose inside

i got lucky with the weather this morning got the inlet manifold back on reconnected the electrics and turned it over waiting for fuel to purge from the injector lines with fingers crossed, no fuel meant nackerd pump i was very relieved to see fuel comming from the injectors so i reconnected them up and she fired up 1st turn of the key:clap:clap:clap

so it is possible to replace the most common seal on these pumps without removing the pump at all, you need a few tools, seal pick, new seal fleabay and balls the size of coconuts

sods law says now the pump isnt leaking from the O ring and upto full pressure one of the other seals will leak

i will do a proper write up with photos using the old pump should any one else have this problem the net is full of usefull guides to these bosch units but there not for the electronic version we have in our TDIs. i am sure the other seals are even easier to replace than the distributor head as nothing can fall out.

if you have the TD version beware you may have extra springs inside which would fall out if you do what i have done

test drive complete all is well with the car :thumbs:thumbs


:augie:augie

 

[trophymick]

Don't you just love happy endings.:thumbs

 

[Sweety]

Congrats:clap:clap:clap

 

[solarman216]

yes well done, be nice to see a pic guide for others to see, Rick

 

[davenclaire]

sooooooooooooooooo

i was going to settle down and start my write up and take a few photos to show the seal and injector head thought id take a few on car photos to and disscoverd the pump is again wet nothing like it was when the O ring was leaking it looks like my prediction of fixing the O ring mite cause another leak has come true. :doh:doh

looking at it i think its the electronic actuator thats weeping now just making the pump wet. after my mammoth O ring reseal im now thinking i mite pull the pump this time and do all of them on the bench i have a complete kit sitting here and then i can decide which method is the best/easiest way of resealing these pumps.

this will have to wait tho with all this bad weather i dont fancy standing outside in the wind and rain doing this and we cant have the car off the road with an elderly inlaw who needs looking after and transporting about.

its hardly leaking at all just a weep but hard to see where from its common for these seals to go when i took out the old O ring it was hard and squared off with age.

 

[davenclaire]

hopefully this is a photo of the top and middle pump seal having looked again at the old pump i have here to play with looks like i will attempt these seals again with the pump on the car i see no reason to remove it as that carries the same worries as before regarding extra parts to remove effecting timeing etc etc

 

[solarman216]

Bum deal mate, but on reflection (easy with hind sight isn't it) just another reason to remove the pump and do ALL the seals cos if one has been effected by other than diesel, then they all will be, if you can do a nice pic trail and written description of the job, it will be worth puting in the downloads, with your name in lights, Rick

 

[davenclaire]

here are the leaky seals that need to be done can still do it on the car should be much easier this time around

top cover removed from pump exposing the internal temp sensor

 

[davenclaire]

here is the temp sensor and throttle actuator housing removed exposing the middle leaky seal

 

[davenclaire]

http://www.youtube.com/watch?v=uyxZ0sfPbB4

go straight to 4 minutes 20 seconds shows the seal thats now leaking as i said before common seals to fail im just following what other have done before

 

[solarman216]

that is good, but what we need for the downloads is a start to finish pic and write-up from all that is needed to remove the pump, then striping and replacements then re assembly, I did similar for the installation of a LOKKA front diff auto locker, did not put it in the downloads as relatively unimportant, only to those dedicated, and they can find it if they need, have a look, Rick

 

[davenclaire]

that is good, but what we need for the downloads is a start to finish pic and write-up from all that is needed to remove the pump, then striping and replacements then re assembly, I did similar for the installation of a LOKKA front diff auto locker, did not put it in the downloads as relatively unimportant, only to those dedicated, and they can find it if they need, have a look, Rick

yep i have every intension of doing so iv taken inspiration from lots of places on the web here is a very good guide
http://www.youtube.com/watch?v=NuRI8EovEmQ

 

[davenclaire]

another update

well iv only gone and had another go at my leaky pump this time doing the top and middle seal this time i took a different approch i removed the power steering pump and moved it out of the way to give me more room and again removed the inlet manifold, while i was in there deep in the engine bay i took my mini banjo filter out bloody thing was rock solid in there so had to drill the brass bit out before i could get it out, look at the state of it.

im glad to report all is back together and running like a dream i booted it a few times on some local roads and hills and it went like stink proberly due to removing the mini filter more than replaceing the leaky seals

i have started my write up its epic and i dont want to miss anything out it should make a good step by step guide to resealing the Ip on the car. im a happy bunny

 

[solarman216]

yep same minifilter as yours removed on my off road motor plus maff amp and in low box permanently so problem now is have to be very careful not to break front shafts which I have found to be a weak point, so it is a case of backing off the loud pedal at the right time, Rick

 

[davenclaire]

yep same minifilter as yours removed on my off road motor plus maff amp and in low box permanently so problem now is have to be very careful not to break front shafts which I have found to be a weak point, so it is a case of backing off the loud pedal at the right time, Rick

mite have to look at this maff amp as im likeing the extra power the car has now its all fixed fingers crossed. it could be due to a few factors mini filter removed, pump working at full pressure now their are no leaks and iv gone and sealed the inlet manifold to cylinder head with new gaskets and sealer as i found it leaking from a couple of the old gaskets.

all in all its running better than ever the wife just came back from a test drive just to make sure it wasnt my imagination and all she said was "bloody hell goes like shit of a shovel never been that good ever" bless her

next think on my list of too dos is replace the rear diff oil tomorrow then finnally a new set of shocks and hopefully thats it for a while

 

[John B]

Hi, what year is your terrano as im wondering if mine has got one its a 2004 ?? Mini filter that is :doh

 

[davenclaire]

1998 you could have one easy to see you only need to take off the banjo bolt on the Ip dont loose the sealing washers there are 2