Mk3 TDI fuel pump repair/rebuild in Sydney???

[Gigitt]

So the fuel pump has decided to start pushing diesel out the bottom half rather than out the pipes.

I take it it needs a full seal overhaul?

Any one know a good place in Sydney?

Or should I risk a US$1300 rebuilt from Boraparts?

I'm in Bundaberg QLD ATM returning to Sydney late this week.

Any help is appreciated.

[gldgti]

Theres a Bosch Diesel service place in Gosford. I've spoken to them a few times - they are pretty knowledgable but I;ve never had them do any work for me. (Mainly because I end up doing it myself).

If you have the patneice theres no reason you can't do it. You just have to buy a seal kit. Its a little daunting but if your pump is only leaking externally and still actually functioning, it will be an easy job.

Happy to help with advise or whatever. Heck, if you want you could bring it to my place in gosford one saturday and I'll help you.

[Jarred]

I got a reconditioned one from overseas, but it was a damn sight cheaper than 1300 bucks.

unfiortunately, I can't remember where it was from, but I think it was called miataparts or something.

[gldgti]

Jarred - did that one work for you?

miataparts, emaita, dieselvw, hansdieselparts, and a few other aliases are all the one company. The dude has a pretty bad rep. I have bought a few things from him and its hit and miss with the quality.

Last time I bought from him my credit card details were stolen and some punks in europe spent about $1000 on train fairs 'on me'. Luckily the bank came to the party on that one.

Just FYI

[Jarred]

All good for sharing, the site does look slightly, hmm, sketch.

Pumps working great though. IIRC it was like 600 bucks or something. (I could be wrong, it was a while ago now)

[Gigitt]

I got a reconditioned one from overseas, but it was a damn sight cheaper than 1300 bucks.

unfiortunately, I can't remember where it was from, but I think it was called miataparts or something.

Yeah $1300 is shipped but there is a $300 core return charge so it is about $1000.

@gldgti
I'm looking at just getting a Viton Rear Pump Head Seal Kit:
viton seal kit
with a few extra o-rings.

Dieselgeek do have an instruction guide for 'swapn' o-rings: TDI Pump Head Seal Replacement Procedure

Pretty sure this is the o-ring seal swap you were talking of.

I should be capable of doing it... I have done an Injector nozzle swap on the TDI, and a de-solder ECU chip upgrade... so this should be of similar delicacy.

Going to have a look at the car after work.
I have to still order the o-ring kits. but hey... if it arrives late next week then next Saturday is ground zero!

Just hope there is nothing else wrong with the Injector Pump...

[gldgti]

Just hope there is nothing else wrong with the Injector Pump...

Unlikely to be anything wrong mechanically. They are made to work just about forever if they have good fuel running through them and they dont sit still for long periods.

It can be tricky to get the head back on with all the springs in the right places. Takes patience. If you can manage it, its much better and safer to do it with the pump off the car - which means also having to re-time the engine afterwards. You can do it with the pump in situ but theres risk bits will fall out of the back and then you have to get them back in there again.... hehe.

Having a tub of petroleum jelly is very helpful for 'sticking' bits in the right spot for reassembly. The vasoline holds things in place bit dissolves with the fuel once its all back together.

[Gigitt]

Just ordered a seal kit and 3 viton o-rings.
should be here in a couple of days.

Took a look at the car today... battery flat so could not start it to see the leak. Was toild it is undewr the head at the back of the pump.
Will go back tomorrow to test pump leak with a charged battery and then get it towed back to mums place into the garage so I can work on it.

Will let you know how it all goes

[Gigitt]

Started the TDI today no noise in the pump, just leaks a bit... More like it dribbles. There is a top seal leak as there are bubbles coming out the join - this is good as this is the easiest seal to replace. Once I fix this then I can determine if it is leaking elsewhere and then I tackle the harder to replace lower seal and or the head seal.

[Gigitt]

FIXED!!!

Well it was just the Top and Bottom Injector Pump Seals leaking.
I replaced them with out any hassles.
Head lined up to my markings... started 1st go.
Was a little high in Inj.Quanity ~6-7 so I lowered it using the hammer mod to about 3.5, rpm ~903
Took it for a spin... laughing!
So simple a fix.

Old seal were just compressed and hard - no wonder it was leaking.

One Happier TDI'er