[Vwdiesel] Rebuilding injection pump

S Boser java at xprt.net
Mon Dec 5 04:57:08 EST 2005

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.

----- 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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