[Vwdiesel] FI pump leak, expert help needed

[gary]

A gasket set from a Bosch dealer is only ~$28.

The most difficult part is the pump head oring that you are describing.

I have torn apart two different pumps in the past and have successfully
reassembled them.

On my current P/U, I removed the pump, and removed the screws that hold
on the pump head and slid it out about 1/2in... just enough to expose
the oring. I was able to work the new oring over the end of the pump
head and into place. Bingo! No more leak. I subsequently replaced all of
the other accessible orings as well such as the cold start lever and the
opposite one as well as the top cover seal.

Probably the next hardest job is to remove and replace the main shaft
seal. Find yourself the appropriate seal puller and this should be a
piece of cake.

-Gary

Libbybapa at wmconnect.com wrote:
> In a message dated 2/25/06 6:20:06 PM US Mountain Standard Time, 
> stephensrw at stn.net writes:
> 
> 
>> What can I do?  I do not have money to send the FI pump away for a rebuild.
>> Could this be as simple as removing the allen head bolts (4?) that hold this
>> block on and finding a large O-ring that needs replacement?
>>
> 
> It could be, and is except for one added complication.  There are a few 
> critical bits (small bits that can easily get jumbled) that need to be reassembled 
> properly.  When I suggested to a local diesel place that I was planning on 
> replacing that oring on a pump of mine, the fellow litterally laughed out loud 
> and said, "You'll never be able to get it back together again."  He said that 
> they would charge some $300 to replace that o-ring. Taking that as a challenge 
> in my usual somewhat rebellious way and figuring I had nothing to lose, 
> considering there was no way in heck I was dishingout that kind of money for an 
> o-ring replacement, I went ahead and carefully dismanlted and reassembled the pump. 
>  It worked fine afterwards.  You will want to get the proper o-ring of the 
> correct material and pay attention while dismantling, but it is not hard.  Make 
> sure that the return line is unplugged back to the tank, as if it gets plugged 
> it will cause lots of pump leaks.  
> 
> Andrew
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