300 TDI Fuel Injector Pump Leak - Advice please

**gozzie** · 5th April 2009, 08:06 AM

Well if its not one thing its another...

I have traced a fuel leak to the fuel injector pump. I have done a serch of posts for information and have thoroughly scared my self to death at the price of rebuilds.

My leak was coming from the small bolt at the very centre of the injector pipes. I put a socket on the bolt and was amazed at how loose it was. I have tightened it and the leak appears to have stopped.

I shall keep an eye on it to see if the leak has finally stopped.

Do you think this is the end of it, or do I have a potential problem with the pump.

Thanks

Gozzie

**B92 8NW** · 5th April 2009, 08:47 AM

Hell. Did you keep track of how many turns you gave it. I'm pretty sure that one at the back in between all the injector lines is the Jesus bolt.

**Ace** · 5th April 2009, 09:19 AM

keep an eye on it, when it leaks from around where the throttle mechanism is then its rebuild time. I dont want to scare you but mine was at the bad end of the scale and needed a new casing and everything and it cost $2500, a new on is $3500.

A typical exchange from Bruce Davis is around $1200, if yours is in reasonable condition and easily overhauled. Matt

**gozzie** · 5th April 2009, 12:52 PM

When doing up the bolt it only took 4 clicks of my ratchet to tighten, I did not do any more for fear of over doing it.

I have just done a 100k trip and engine running just the same and not a single drop of fuel has leaked.

I am going to the UK next week for a holiday. I think if I picked up a new injector pump I would be quids in even if I eventualy sold it.

I will keep a close eye on the pump just incase. I am hoping I will not have to spend any more money just yet as I spent another $1000 on it on Friday. I love my Disco but at the moment it seems I am rebuilding her from the wheels up!

Can't complain though as I did my research here before I bought one so I knew what I was letting myself in for.

Cheers

Gozzie

**Ace** · 5th April 2009, 02:00 PM

What year is the disco Gozzie? and how many km's has it travelled?

I have been doing bits and pieces to mine over the last 12 months. After 4yrs of trouble free motoring from her, and 4yrs of abuse off road its finally starting to see things wear out, which i am fine with. I just do one job at a time as they crop up, but get reassurance from the fact that once you have done the bits and pieces that need doing she will do another whole heap of trouble free km's.

I looked at getting an injector pump from the UK aswell but was told that there is some sort of difference between those on Australian models to some UK models so make sure its the exact one before you spend the dosh and bring it back.

**lambrover** · 5th April 2009, 02:24 PM

you said it was the bolt in between the injector lines, if this is correct you have nothing to worry about, that little bolt has copper washers on it to seal and you remove that bolt to fit a dial indicator for timing the pump. it is just an access port for timing it dosn't change any settings.

**gozzie** · 5th April 2009, 02:46 PM

Many thanks Lambrover for putting my mind at rest.

The small central bolt is the one alright. I think it has been leaking a steady drip for some considerable time. I did not see any washers but to be honest it was difficult to see, as I had to use a mirror.

Now to tackle the rest of the leaks!

Thanks

Gozzie

**gozzie** · 5th April 2009, 03:13 PM

ACE

Thanks for the information, I doubt I will bring one back if I stay fuel leak free but I am glad it looks like I wont have to. That was some serious money for the injector pump and I suppose if it was to be changed then getting one or overhauling mine here to incorporate the pump tweek at the same time would be the way to go.

I have had my 1998 Auto TDI since Jan 2008. I bought it with 113,000 on the clock and since then I have done 14,000 K's. The main reason for buying was to tow a boat which we bought in February this year. Towed the boat back from Noosa to the Gold Coast with no effort, ( except for a few very long hills that I would have been wise to get the revs up first).

Since then I have had done:-

Lift pump
Main belt tensioner
breather hose
Upper oil cooler pipes ( replaced with non leak type )
Oil pressure switch
Rear Donut
Steering Damper
Centre A frame ball joint
Passenger window regulator & lift Motor
new Cam belt kit
Radiator Clean & Flush
The Head over heated needed to be re worked ( ouch!)
New expansion tank
5 new tyres.

Now I really do not think my Disco was treated with the care and attention that it deserved. A lot of the ball joints and seals have needed replacing as they perished away to nothing.

I probably paid to much for it,(don't ask) but to be honest i was looking for a long time up here on the Gold Coast and very few were on the market.

As I only travel approx' 12000 K's a year I am intending to keep the Disco for a long time. I keep telling myself that it is worth paying to have these items fixed because it will pay dividends in the future. I would just like to go one service without a big ticket item to fork out for. I think I am almost there... Damn I just forgot my PAS pump is leaking and I was qouted about $480 for a new one. As it not a huge leak I am living with it for the time being.

How does my little shopping trolley of parts compare with you?

Cheers, Gozzie

**Ace** · 5th April 2009, 05:03 PM

My injector pump died because i didnt realise there was another fuel filter back near the tank and it filled with algae and the algae effectively ate the inside of the injector pump. So it was my fault, they are a pretty reliable item and if you keep up to date with the fuel filter changes it should last you a long time to come.

My disco is the same age as yours but mine is about to tick over 275000km, and would still be on the same motor if i hadnt been an idiot and not listened to my head and checked a slight coolant smell, which turned out to be a leaking heater core which cost me an engine and alot of money.

When you replaced the lift pump did you replace the fuel line running from the lift pump to the fuel filter housing thats bolted into the fire wall?

See my thread here, http://www.aulro.com/afvb/projects-t...pump-leak.html

Alot of people just replace the lift pump over and over again and curse at it, but if you replace the hose, you will never need to replace the lift pump again.

I have had the disco since Sept 2004 so have spent alot of time getting to know the vehicle and re-engineered some niggling issues such as the fuel line one.

But stick with it mate, its 10yrs old now so stuff will wear out with age aswell as use, and if it hasnt been looked after aswell as it could have then you might need to sort a few things out, but stick at it, they are a top truck and well worth keeping long term.

If you arent mechanically minded give some of the basic jobs a go yourself, there is plenty of support on here and job like wheel bearings and basic servicing isnt really that hard, you just need a few basic tools and some patience. I started changing oil, i can now rebuild a diff, fitted lockers, suspension, fitted a new clutch, had the transfer case out 3 times to fix a leak that i kept creating (i got it right with Langy's help) and just pulled the old motor out and put a new on in. they are easy to work on, and knowing your car helps when things happen on the side of the road aswell.

Matt

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