Injection Pump Leak

[ArmyOfRabbits]

84 RaBBit Diesel, leaking bad from the injection pump. One leak source is the line in from the filter where it bolts onto the pump. The other visible is the bolt head to the rear of the first leak that requires some funky vw tool. Final possibility is the cap on the top of the pump with four allen head bolts. Anyone know if these three seals can be done with the pump in the car? Got any links with schematics, gaskets, instructions? New to diesel but love it. Thanks.runaround

[zagrot]

the fuel intake and outlet are of a banjo bolt arrangement and use copper washers for sealing. replace the washers with new ones of the same size, or if the originals are not too badly deformed they can be anealed with a propane torch to make them crushable again (just heat them to a red heat and allow them to cool in the air; don't quench them in water, and be careful not to melt them).

"the bolt head that requires the funky vw tool," i assume is triangular and on the side of the pump case. allow me to advise you not to remove those because the part that it holds inside the pump may shift and require partial disassembly of the pump to reinstall (however if you have the pump's top off there is plenty of access to the internals to be able to do this). the bolts on the side use aluminum washers for sealing, maybe if you try to tighten it a little bit the leak may stop.

if the pump is leaking around the cap it is due to a bad seal that is replaceable with the pump mounted on the engine, but that requires disassembly of the throttle lever assembly and subsequent resetting of the idle spring/ governor spring assembly. that is not difficult to do but is difficult to describe. the following link is to another forum that details the pump reassembly, but does not detail setting the governor/ idle spring assembly and the throttle lever on the top of the pump (if these parts are not set correctly on reassembly the engine will start and idle, but will not throttle up). i'll see if it is possible to install a new cap seal without fully removing the cap. if so i'll post here again.

this will give you an idea of what is inside the mystery box, what you want is toward the middle of the tutorial. i definitely hope you don't use dialup.

http://www.vwdiesel.net/phpBB/viewtopic.php?t=4353