[Vwdiesel] Rebuilding injection pump

[Razvan Florea]

A few days ago I noticed that my pump is leaking too.  I went to the 
shop(Garrett and Delphi service) and they charge about 110 US$ for removing 
IP, full rebuilding including seals kit, mounting  and timing. Since I don't 
have much time and zero expertise on IP I am thinking to go with the shop. 
Is that a fair price? The pump is 212k km, on 1,9 AAZ TD 1993 engine!
Thank you,
OT: Today just signed the lease for '05, 2.0 TDI PD 140 Hp Golf. My dream 
car is two days away! Just had to share with you guys!
All the best,
Razvan
'78 1,6 NA Glof (gone now)
'84 1,6 NA Golf
'93 1,9 TD Golf
'05 2,0 TDI PD Golf (waiting)


----- Original Message ----- 
From: "S Boser" <java at xprt.net>
To: <vwdiesel at vwfans.com>; "Sandy Cameron" <scameron at compmore.net>
Sent: Monday, December 05, 2005 11:57 AM
Subject: Re: [Vwdiesel] Rebuilding injection pump


> Thanks I'll give that a try as a short term fix, I still want to try my 
> hand at rebuilding the pump, but better to not have to rely on my 
> incompatance on a car I need to get around with.
>
> Steve
> ----- Original Message ----- 
> From: "Sandy Cameron" <scameron at compmore.net>
> To: "S Boser" <java at xprt.net>; <vwdiesel at vwfans.com>
> Sent: Sunday, December 04, 2005 8:52 PM
> Subject: Re: [Vwdiesel] Rebuilding injection pump
>
>
>> At 06:51 PM 12/4/05 -0800, you wrote:
>>>Hi All
>>>
>>>Seems around here our injection pumps are starting to leak. A friends 
>>>1980
>> Rabbit was leaking for a while and he didn't notice it, his wife was 
>> driving
>> it and the fuel had saturated the belt and of course the belt let go. 
>> She's
>> trying to talk him into a new TDI
>>>A couple days later I noticed a shiny spot from under my car after a
>> typical Oregon rain, on closer inspection, it appears my injection pump
>> front seal is leaking too.
>>
>>
>>
>> Front (main shaft ) seals are cheap and easy to replace. I did the seal 
>> on
>> the old 1.6 in goldie 70,000 miles ago and still dry. Seal was so bad the
>> xfer pumpwould not lift fuel
>>
>> Don't even have to take the pump off the car.
>>
>> Buy the seal, (less than $10) from a pump shop.
>> Pull the drive sprocket from the pump shaft (it's keyed)
>> Use a puller, and pull on the holes inside nearest the shaft, or the
>> sprocket may shatter, it's cast iron.
>> Take a small flat blade screw driver, heat it, bend the blade 90* to form 
>> a hook
>> Dress it with a file so it is free of burrs and about 1/16" hook.  A real
>> toolmaker could probably shape it in a semi-circle to fit even better.
>> The deal is to be able to punch it through the fabric of the seal WITHOUT
>> TOUCHING THE SHAFT ! ,  and hook it out of the pump body without touching
>> the shaft with anything and scoring it.
>>
>> Brain surgery? yes, but doable even by an old fart like me. Just do it
>> slowly and carefully.
>> Doing it again, I might make a split plastic tube , like the one in the
>> brake caliper sliders, and insert over the shaft to protect it during the
>> operation (maybe a proctologist could do it without hurting anything?)
>>
>> The new seal is inserted flange - in, and tapped home using a short 
>> length
>> of 1/2" copper water pipe.
>>
>> Assembly is reverse of dis-assembly {Bentley}
>>
>> Even though my pump is very high-miles (it's second engine) and the shaft
>> has significant play, it still does not leak after 70,000m / 100,000km 
>> (near
>> enough)
>>
>> Car has 500,000km on it, just broken in.
>>
>> Sandy
>>
>>
>
>
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