300tdi fuel pump modification.

[Hopton1973]

Help! Just upgraded my intercooler but I cant seem to undo the four flat head screws on the fuel pump to turn the diaphragm. I have managed to loosen one screw but the others wont give. I am nervous about shredding the screw head and have sprayed with WD40 to no avail. Any ideas anyone? Surely i don't have to go to a real mechanic to get a screw undone :s

[justinc]

very common, i would suggest a large flat screwdriver at an oblique angle placed on the top of the screw slot and gently tap it around in the anticlockwise direction with a hammer. do not use an impact driver in a vertical direction!


jc

[Hopton1973]

Thanks jc

[THE BOOGER]

Help! Just upgraded my intercooler but I cant seem to undo the four flat head screws on the fuel pump to turn the diaphragm. I have managed to loosen one screw but the others wont give. I am nervous about shredding the screw head and have sprayed with WD40 to no avail. Any ideas anyone? Surely i don't have to go to a real mechanic to get a screw undone :s

They can take a bit to crack loose. Did you get a allisport intercooler they say to turn the diaphram 180 degrees we did one about 6 months ago and the EGT went off the scale try 45/90 deg to start with and build up from there we did a head gasket so being wise after the fact
Oh and make sure you have an egt gauge

done right it will make a huge inprovment

[rick130]

IIRC I think I used a gun screwdriver kit which uses fitted drivers (ie. parallel, not tapered sides) and a ratchet drive handle.

I use it for anything where screws are either hard to access or I might have problems undoing a screw.

An ordinary screwdriver tends to 'cam out' due to the taper of the driver, a parallel sided driver that's fitted exactly into the slot won't.

[Blknight.aus]

I use my impact driver, its got a nice fat rubber sheath on it thats about the thickness of a V can. (and its got parallel ground tips)

[Hopton1973]

They can take a bit to crack loose. Did you get a allisport intercooler they say to turn the diaphram 180 degrees we did one about 6 months ago and the EGT went off the scale try 45/90 deg to start with and build up from there we did a head gasket so being wise after the fact
Oh and make sure you have an egt gauge

done right it will make a huge inprovment

Yes, got the Allisport intercooler and already a significant difference as the turbo was already upgraded before I got the car. The previous owner has said not too touch the fuel pump but not sure why. It can't hurt to have a tinker can it? Maybe I should get the EGT first to cover my ar*e. Thanks.

[Blknight.aus]

Come on over if you like, I'll be tweaking SWMBO's disco at some point. (and fitting the boost gauge properly and the EGT gauge.)

[Hopton1973]

Thanks Dave that sounds really good. When you know when email me at hopton1973@hotmail.co.uk. Thanks Jeremy.

[Hopton1973]

Thanks for the advice