[Vwdiesel] '00 Golf IP pump seal problem

[Bryan Belman]

Nice job on diving into the pump to do the seal replacement.  Air bubbles coming to the pump from tank could be a number of things.
a small amount of them in an old car like this are normal unless you replace everything from the tank to the fuel filter.
you could still have the water seperator box under the passinger rear seat, try by-passing that as a first step to finding the source for the air bubbles coming from the tank.
 
injector return lines can add air bubbles but you would only see those going OUT of the pump and most folks do not have a clear tube on the OUT injection pump banjo to the plastic line that takes the extra fuel back to tank, but some cars do have this.  these are easy to change so change them out.
 
 

Bryan Belman, Pt. Pleasant, NJ
04 Jetta Wagon TDI PD, 100hp, 5sp -- running :<)
92 Jetta 1.6 Eco-Turbo Diesel, 5sp -- running :<)
82 Diesel Westy 1.9NA -- running :<)
70 Type 1 stock Elm Green Beetle -- Under Restoration :-)

From: Stephen Sherman <spsherm at msn.com>
To: vwdiesel at vwfans.com
Sent: Monday, September 5, 2011 11:22 PM
Subject: Re: [Vwdiesel] '00 Golf IP pump seal problem

Well a bit more as things unfolded...

Car drove well for a week, then one day I noticed a strong fuel smell. Looked under the hood, and the IP was leaking from the seal below the QA. Pretty obviously that gasket from the wet area and dirt.  Order the gasket kit and special tool, and replaced that and the top cover gasket. Got the QA adjustment back into the working range (good idle now), and things seem OK. At least no signs of new fuel leaks around the IP.  Definitely would suggest multiple alignment marks if you do this, as I needed to rely on a second set to get the QA in spec. (The epoxy chipped off as I took it apart, so wasn't able to use those marks)

Still have some air leak, as I can occasionally see a stream of bubbles in the fuel clear line. Hoping its not one of the IP gaskets I replace. Will replace the injectors furl return line as it is getting pretty old. And take a closer look at the main return and fuel lines. But at this point, the only symptom is the air bubbles in the fuel line. No obvious leaks anywhere.


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