injector pump leaking 300TDI

Don't mean to hijack your thread Peter, but I'm curious about the importance of having the pump internals on maximum compression.

As per earlier thread references, I took my pump off to do the o-ring seal change, so my pump was at the timing pin position throughout.

But if I hadn't, I probably would have chosen to do it with minimum internal compression - that is between the cam ring lobes - thinking I was reducing (slightly) the chances of things going SPROING! Seems this thinking is wrong but I still don't understand why.

2 reasons.

1. without the return springs that push the guts of the pump back against the cam plate when you work the distributor head out the internals can come out of alignment and engagement.

2. the springs push the head out for you so you dont have to fight with it. this means it works its way out as you unwind the bolts so you keep it under control. as opposed to have to wiggle it and pull.


both these reasons are why you want the spare bolts that are a little longer than the fitted ones to act as guides and to give you some more thread when you start to pull it back in.

On my 300 Tdi 2 of the bolts were 2mm longer as they hold the bracket on. I used these with the bracket removed.

This was so much easier on the bench held at TDC (full compression) with an insert.

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Originally Posted by Blknight.aus

2 reasons...

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Thanks Dave. Makes perfect sense when you explain it like that.

Any technology sufficiently advanced will appear as if magical.

part of my job is to unmagic my trade.

I do believe the saying goes "Landrover, making mechanics out of drivers since 1948". I like to think of it as just doing my bit to maintain the tradition.

Thanks not to all the replies especially Blknight. We put the air con to one side as well as the expansion tank and had reasonable room to to attack the seal bin rather injector head. It was fiddle but quite possible, put it all back together and it started runs well as it nwas before the job but now without leaks.

BUT when we took the fuel shutoff switch out the plunger and Spring was covered in very fine metal flecks ????? As we said, it started and runs well any suggestions as to what to expect or should I look to a complete over haul or a new pump??? Peter

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Originally Posted by pjlhat

Thanks not to all the replies especially Blknight. We put the air con to one side as well as the expansion tank and had reasonable room to to attack the seal bin rather injector head. It was fiddle but quite possible, put it all back together and it started runs well as it nwas before the job but now without leaks.

BUT when we took the fuel shutoff switch out the plunger and Spring was covered in very fine metal flecks ????? As we said, it started and runs well any suggestions as to what to expect or should I look to a complete over haul or a new pump??? Peter

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Whoa! Easy on the mega-sized red font, please. And how about something resembling English too, please? Am I reading this as a shot at Blknight? - or just a bit of a slightly too 'happy' Sunday arvo?

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Originally Posted by pjlhat

[FONT="Comic Sans MS"]Thanks not to all the replies especially Blknight. We put the air con to one side as well as the expansion tank and had reasonable room to to attack the seal bin rather injector head. It was fiddle but quite possible, put it all back together and it started runs well as it nwas before the job but now without leaks.

BUT when we took the fuel shutoff switch out the plunger and Spring was covered in very fine metal flecks ????? As we said, it started and runs well any suggestions as to what to expect or should I look to a complete over haul or a new pump??? Peter

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defonted for the sake of screen saving... :)

thats usually bad, it means the internal hardfacing is starting to come adrift from somewhere.

Its going to mean pump off eventually.

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Originally Posted by Blknight.aus

defonted for the sake of screen saving... :)

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Now, why didn't I think of that...

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Originally Posted by Leo109

Now, why didn't I think of that...

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Coz mechanics think differently to the rest of us:D