Leaking injector pump

[drmike]

Looks like my injector pump on the 200 TDI is leaking but I can't work out where it's coming from.

The four output unions for the injector pipes are dry as is the input pipe and the return from the injectors.

I would say it was leaking where the top and bottom parts join and seem to be held in place with allen bolts but there is diesel higher up that that joint although that might be capilliary action.

Are there any likeley suspects for a leak?

About 6 weeks ago I did take out the big allen bolt that sits behind the throttle spring - but that surely doesn't have any fuel behind it - or does it?

Could the case have fractured do you think?

I assume a leak like this would be an MOT fail which I had booked for Friday.

Grr - as always any help will be appreciated!

Mike

[hobbit]

Not necessarily fracture but may be a seal or gasket leak, need to wipe it down and have a good look when running it up

[drmike]

Thinking it over I think I agree that it will be a seal or gasket. Is it possible/easy to replace such things or is it a specialist job?

I'm game for anything as I just want to get it running OK and ideally by Friday when it goes for an MOT! I can't afford a replacement pump right now either.

Mike

[hobbit]

Anything injector pump I dont play with myself, but some people do, its a case of what is leaking first then seeing if its a simple plate or a seal that means a more complicated operation

[drmike]

It's almost certainly the throttle spindle seal. That seemed to be where it came from after a good clean up and when I took the spring etc. off you could see the diesel coming out.

Local diesel boys say 25 quid parts or 60 quid fit. So I think they'll be getting 60 quid as it looks a bit tricky to fit. I may look at the parts and see if I fancy it but for 60 quid it's probably simplest if they fdo it.

Mike

[drmike]

Damn we had crossed wires and now the guy knows it's a 200 TDI he says it can't be done pump in place.

As I recall taking the pump off means removing the radiator, the timing cover and a whole load of other bits too as well as locking the timing.

I can see this costing a bomb or being a lot of tricky work just to get the pump off.

Mike

[Porny]

You can get a tool that you use to lock all timing belt etc in place (you don't even have to remove the front cover)... and then the injector pump can be simply removed.  

As you mentioned, otherwise it's a front end strip down again, which in all honesty isn't particularly difficult, but handy to have the correct tools....


Ian

[drmike]

Ian

You've cheered me up and I've looked at the workshop manual. This says you need to get TDC on No 1, lock the flywheel through the hole in bell housing and lock the pulley. Then remove the pump.

Is it really that straightforward?

They also talk of rotating the crankshaft two full revolutions and checking this that and the other - do you need to do this?

I'd guess if you have the tools and have done it a couple of times then it's a quick enough job or does it still take a while?

Thanks again for your thoughts which have cheered me up.

Mike

[Porny]

Ian

You've cheered me up and I've looked at the workshop manual. This says you need to get TDC on No 1, lock the flywheel through the hole in bell housing and lock the pulley. Then remove the pump.

Is it really that straightforward?

With tool LRT-12-045 it is....
(which is one I tool I keep meaning to buy... or get one to copy )


If you can't find one of these, I have got all the other tools needed to remove the timing belt  

Rotating the cambelt and re-tensioning isn't always needed, but I always rotate and recheck as a matter of course...  

In all honesty I don't know how long it takes to do a cambelt, but then I don't work in a garage or do it for a living (though I do work with engines all day long!), but the last I did took 7 hours... but this also covered cleaning everything properly, all new oil seals, etc etc etc.  And drinking coffee and eating etc.
I have done quite a few of them now, but always take my time rather than rushing them...

Obviously yours would be split over a couple of days, whilst you sent your pump to be repaired..

You'd probably be looking at a couple or 3 hours to get everything stripped down and the pump removed.... without going at it like a bull in a china shop!!  Then you could clean everything at your leisure, and put the pump back when done.  

I've no doubt people would do it in less time, so could I if I really wanted too.....  


Ian