Thread: PUMP LEAKS AND MORE...........

Hi all,

Have Disco 1 1995 TDI 300, not worth much these days so a leaky injector pump seemed an unecessary expense.

Using "dieselgeek.com" head "o" ring replacement procedure and
ebay seal kit from "protech_2008 (286)" KIT # ZZRGK223/1.

Procedure is pretty similar to Diesel Geeks info, just fired it up with no leaks, took me about 6 hours, could probably do it in 4 hours now.

Have to remove Fuel Lift Pump, injector lines, and fuel hoses so acces is good as the process is fiddly. Bleeding a cinch.

4 X 6mm 50 mm long hex high tensile bolts
2 X 6mm 45 mm long hex HT (for replacement if required)
T30 torx socket, preferably 1/4 inch drive.

5mm Hex (allen socket) again best in 1/4 inch drive.

The kit is about $45 AUD plus freight, I have measured up "O" ring and can say an alternate MS type "O" ring in the -140 size (2.237 inch) Inside Diameter , 0.1 inch thick or similar would be suffice.

The kit supplied is a "viton" type "o" ring, which stretches better over head assy. eg its better than the bosch original "o" ring.

Few tips for pump body o-ring cx:

1. For discovery bolts holding body some are torx 30 and others 5 mm allen.

2.Fitted dial gauge with an old sun visor rod to ensure pump is on stroke, eg spring inside at max compression (opposite of normal timing)

3. ONly bring pump body back enough to change o ring, eg no more than 1/4 inch,
also use vaseline or similar lubricant before pushing body back together

4. Bracket on engine side only has a very small clearance to slide o ring past,
i managed to do this but would suggest removing inner bracket from pump


regards
OZ

Attached Thumbnails
FAN SPANNER old "O" ring new "O" ring sockets sizes dial gauge to set max compression of pump internal spring

About to attempt shaft seal insitu, may remove as i have to do belt.

Question for "BLACK NIGHT", TDI 300 pump sprocket has no woodruff key only
taper, i guess if removing this one would have to mark/match sprocket and taper shaft to allow shaft seal change.
I may use timing dial indicator as a double check, 1.57mm before TDC ?

I am aware tdi 200 pumps had a locking device on side of pump, and also used woodruff key to lock sprocket.

Few more pics from my pump head o ring change for those interested:

THESE tools essential, note i used 1/4 drive and 3/8 drive T30
pump tools sml.JPG

BRACKET GAP WHERE O RING HAS TO SLIDE PAST, better to remove bracket
ineer bracket gap sml edit.JPG


OLD "o" ring before removal, note how flat it is, hard as a rock too
old seal flat sml.JPG

I use stahwille 1" 1/4 combo spanner to remove fan as these spanners are very thin

Also note bolts on back of pump head mixture of T30 and 5mm hex, make
sure you have the correct tool before trying to undo.
Gold anodised bolts are 5mm. black are T30 with a very shallow head

Resealed pump back in june 2012 , going well

regards
OZ