Thread: injector pump leaking 300TDI

Can not help you with the leak but if you scroll down on "reply post", there is a button called "manage attachments". Click on this, choose your pic and upload. This should put your pics in the thread (as a clickable thumbnail pic).

sounds like the top plunger seals have gone, if its the big nut thats in the middle of the head where the injector lines screw on or the cover screw is MIA/leaking.

it might also be the check valves that crown the injector pump or the distribution head/body seal failed.

if its coming from higher up then it might be your cut of solenoid and if its coming up higher than that then its the internal seal from the boost aneroid pin has failed, the under side of the cam has filled with diesel and is leaking out the atmo vent.


wash it down thoroughly dry it well dust it with talcum powder and track the leak down flick up a pick and we can give you more info.

Many thanks Blknight will try and get a photo tomorrow if it is as you suggest is there a seal kit and can it be done with out removing the pump....and by a layman?? Peter

Hi pjlhat,

If it's the o-rings in the distributor head at the back of the pump (as my recent leaks were), it's probably best for mere mortals to remove the pump for replacement. Pump removal and replacement is not as hard as it might seem if you've never done it before, and it definitely makes it far easier to thoroughly clean the pump before working on it and makes the replacing the seals much simpler.

There might be some useful info in this thread: 300Tdi injection pump.

From my last post on the last page of the thread above:

"Things learned during this saga:

If your pump is leaking from the front top area, it's likely to be the throttle shaft bush and seal. Not too difficult a job and can be done in situ.

If your pump is dribbling from the distributor head on the back of the pump, I suggest checking in this order:

1. Make sure the injector pipe unions are tight.

2. Make sure the delivery valves are tight in the distributor head.

3. Check that the hex head plug in the middle of the large triangular plug is tight. This small plug has a copper washer under it that can be replaced.

4. If the above doesn't stop the leaks, my next suggestion would be to remove the large triangular plug and change it's o-ring. With the right socket, it's a pretty simple job and can be done in situ (see previous post).

5. If it's still leaking, then you'll probably need to replace the large o-ring that seals the distributor head to the pump body. Dave says this can also be done in situ (and I'm sure he can) but for we mere mortals, I think this is best done with the pump out and held vertically (dist. head up) in a vice. All jobs on an injection pump need to be done with great attention to cleanliness.

I found this guy in the UK very helpful: HOME - HOME - www.diydieselshop.com. He sells parts on eBay as "allmakes-diesel-specialist" and provides detailed installation notes."

Please PM me if you think you might need to borrow the special triangular socket mentioned.

Many thanks Leo, have had a good look and if I remove the compressor, air cleaner and maybe the lift pump I think I good give it a go. The kit from the guy in the UK doesn't seem to have an Australian ebay a/c so I think I will have to join the UK ebay.
Peter

Originally Posted by pjlhat

The kit from the guy in the UK doesn't seem to have an Australian ebay a/c so I think I will have to join the UK ebay.
Peter

Seems to still work on my eBay: Landrover 200TDI 300TDI Fuel Pump Seal KIT Instructions | eBay. If you don't need the whole seal kit, send John a message via eBay and he should be able to give your his eBay item nos. for just the throttle shaft seal/bush kit and/or the distributor head seal kit. I've found him very good to deal with.

PS: On my Discovery, I didn't have to remove the air con compressor or the lift pump (well, not until afterwards, when it failed). Defender might be different re access.

PPS: This is the VE pump triangular socket set: You only need the large one unless getting seriously into the innards of the pump (not recommended without a proper clean room, Bosch manuals and several thousand dollars worth of pump test bench...)

Hi. Sorry for late reply.
My almost identical defender had a leak about 12 months ago like this, the other symptom was it took a lot of cranking to start because it wasnt getting fuel. There is a large oring at the back of the pump that can be replaced in situ if you are clean and careful.
Essentially my leak was the distributor oring letting all the fuel out when I was stopped so the pump needed repriming by cranking before it would start. There is some good guides on some vw forums on how to pull the pumps apart as they are the same ad the old diesel golf's.

Hi Thanks for the info, did you have to take the a/c off and lift pump or were you able to work around them.The repair kit should arrive before the long weekend and I hope to attack it then. If I have the same problem it is not as bad as todate it is not effecting starting or running just a pool of diesel on the floor.
Peter