Thread: 300TDi injector Pump DYI gasket replacement?

I would grab a manual and give it a crack myself - I haven't done this repair (yet) but what have you got to lose? I guess they want the rebuild to improve their return rates and bottom line?

If its the gasket between the top cover and main body it is pretty simple DIY.

I had a different leak but I had to take the top cover off so this thread might help you out. ->
FIP ING HELL!! - Tdi Fuel Injector Pump Leak

Skim over the drama and there is some useful info there - at the time of initial post I was convinced I wouldn't be able to fix it myself! Turned out to be simple and only cost a few bucks .

Matt.

if you're handy with the spanners but scared of the pump (nothing to be ashamed about, it is only the most important part of the diesel injection process) and you're willing to wait till Im back from the NT while your parts kit turns up I'm happy to have you do the work at my place in case you need backup.

Originally Posted by manic

If its the gasket between the top cover and main body it is pretty simple DIY.

I had a different leak but I had to take the top cover off so this thread might help you out. ->
FIP ING HELL!! - Tdi Fuel Injector Pump Leak

Skim over the drama and there is some useful info there - at the time of initial post I was convinced I wouldn't be able to fix it myself! Turned out to be simple and only cost a few bucks .

Matt.

Thanks Matt
I think yours was one of the threads I had read but I have been using the IPad and don't know how to save stuff. Now that I am back on a real computer I have printed it all out and read it mutiple times.

Originally Posted by Blknight.aus

if you're handy with the spanners but scared of the pump (nothing to be ashamed about, it is only the most important part of the diesel injection process) and you're willing to wait till Im back from the NT while your parts kit turns up I'm happy to have you do the work at my place in case you need backup.

Thanks Dave, I may takey you up on that, is it KM Deseil that you by the kits from? Looking at the throttle linkage (i have borrowed the photo from Matt) there is a plastic tab which covers one of the four bots which holds the top down. Does all the throttle linkage and spring need to be removed or can I file the plastic away from the bolt? Also does the pump have to be positioned in a certain spot before removing the top?

Rob

On the other end of the throttle spindle is is an internal link that can break so it is advisable to remove the throttle arm and spring so you can push the spindle through the top cover as you pull off the cover. Less chance of ripping the spindle linkage off with the top!

That said I accidentally pulled the top off with the spindle and it did not damage the internal linkage when it separated. I may have got lucky there.

So I suppose it might be possible to carefully lift the top off with the throttle arm and spindle attached and try and release the internal link whilst partially separated, perhaps with a feeler or some jiggling. I don't recommend it though.

If you do push the spindle through you can renew the spindle seal, inspect the bush and shaft for wear - as a bonus.

its easier to do it while its off but match mark the bolt, spindle and plate first.

the plastic tabs are just anti tamper so that the service dept knows if you been b ad and played pump tweekery.

you will also have to remove the fuel limit screw to make assembly easier, I measure them with a vernier prior to removing it and then usually ignore that and wind it in a bit on the reassembly

and yes, KM diesel is where I get my overhaul kits from, (I dont normally go the whole hog as the main springs are exxy and usually not required but are on shelf for easy delivery/pickup)

Thanks Dave, I have been reading up on Matts link and the LR4x4 link nadir looks worth having a crack at. The hardest part looks to be keeping the throttle shaft in the correct location. As the throttle shaft is not leaking do you think I can leave the spindle bush and just replace the O ring? The spindle shaft looks a bit tricky to replace but I assume if the top plate was heated in the oven for a while it would tap out easily. KM were the business I rung today. Do they sell a kit or do you give the part numbers? (They were on the link)

Rob