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VW MKIII-A3/B4 TDIs This is a discussion about MKIII-A3/MkIII Jetta/Golf (<99.5) and B4 Passats (96,97) TDI's. Non TDI related postings will be moved or removed.

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Old September 24th, 2006, 22:46   #46
Bugger
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The return line your talking about. Is it the one on the fuel filter that is held on with the clip?
Thank you. Ken
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Old September 25th, 2006, 05:26   #47
OilBurnerDE
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Quote:
Originally Posted by Bugger
The return line your talking about. Is it the one on the fuel filter that is held on with the clip?
Thank you. Ken
I believe so. On my 97 Passat fuel filter, the feed line come out of the right metal elbow port on the fuel filter. My feed line is clear, so you can see when fuel is being sucked through it.

The return line is connected to the plastic (check-valve?), I just removed it from the front side of the valve, hooked the pump to the rubber line and then covered the open port on the valve with my finger and started pumping.

That is what worked for me.
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Old October 27th, 2006, 14:55   #48
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HI! No part number, but I'm talking to a Bosch shop at the moment. My 96 Passat pump started leaking, too, aboout 2.5-3 months ago. The shop reports they have been overwhelmed with diesel pump repairs recently. they say it's because the diesel fuel is different. I live in SC, and we don't have bio-diesel, but there is something going on to be sure! they say is because just recently, more sulfur is being taken out of the fuel and that creates a problem.
I'd planned to take the pump to them for rebuilding but they cannot do it because it has the electronic interface!
The nearest shop for me is about 250 miles away.
That ain't too good news!
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Old October 27th, 2006, 15:54   #49
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Just finished reading the illustrated instruction on replacing the top and "middle" seals...great article and the pictures are too good!
One thing I discovered about starting a dry pump...refill the pump thru the return line. Disconnect the return line at the filter, and use a tiny funnel or some sort of squirt-bottle with the nozzle modified to fit the fuel line. (You can't refill thru the intake line as it is controlled by the fuel shut-off solenoid valve.)
This trick works good enough that you don't (1) operate the pump dry at first, and (2) you don't grind away on the starter:it starts pretty quick!
PS. Nearby shop won't sell BOSCH "special" tools, either!
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Old October 28th, 2006, 09:48   #50
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I did a how to for the pump head (when the guts fall out..) If anyone gets a chance and look it over. I was in a hurry to get out of here today, so if you see something that is not right please let me know and I will correct it.
Ray
VE Pump head VE Parts illustration
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Last edited by Ray_G; October 28th, 2006 at 09:51.
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Old October 28th, 2006, 13:17   #51
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Wow, Ray_G, good job... BTW Wypij sent me an IM with the URL of a seller for 11mm pump heads fairly cheap... Don't know anything about the seller or the parts quality... (prothe link removed)

I'm having what appears might be a problem with my modulating piston getting hung up, I've been looking for some inside shots of the pump head assembly and you delivered!

BTW: anyone in MA who needs help with a leaking IP can get in touch with me and I'd be glad to help them out.

Last edited by BKmetz; March 3rd, 2012 at 19:35. Reason: prothe link removed
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Old October 28th, 2006, 13:35   #52
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I'm on-line again to announce that I'm going to order parts and special tool from Metalnerd, and go for it!
Since I was successful in removing and replacing the 80-90 VWdiesels' fuel pumps w/o "special" tools, and having the cars run fine afterwards, I feel I can make a go of this too. I'll be using the instructions from a few posts earlier as a guide!
My pump has 990 as the last digits...the parts list shown
at the end of the instruction is a 985...anyone know if the 2 seals are any different?
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Old October 28th, 2006, 14:39   #53
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Nice link on the 11mm pump head. hmmmmmm might have to think about that one. Thanks,
Ray
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Old November 8th, 2006, 13:11   #54
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Quote:
Originally Posted by jollyGreenGiant
Wow, Ray_G, good job... BTW Wypij sent me an IM with the URL of a seller for 11mm pump heads fairly cheap... Don't know anything about the seller or the parts quality... (prothe link removed)

I'm having what appears might be a problem with my modulating piston getting hung up, I've been looking for some inside shots of the pump head assembly and you delivered!

BTW: anyone in MA who needs help with a leaking IP can get in touch with me and I'd be glad to help them out.
I've e-mailed that site and not gotten any responce back. The prices look good, but I'm still new to TDI's so what do I know.

Last edited by BKmetz; March 3rd, 2012 at 19:36. Reason: prothe link removed
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Old November 8th, 2006, 15:01   #55
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I just emailed them today as well, I wanted to know if the pump head they are selling is Bosch or aftermarket, and if aftermarket where is it made. They also sell new TDI nozzles that are 99.00. Kinda sounds like Chinese made nozzles to me. I just wonder about the pump heads as well.
Ray
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Old November 8th, 2006, 15:04   #56
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The just responded to my email. They told me that the pump heads are made by CHJ which means nothing to me.
Ray
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Ultimate cup holder for B4's Dimensions for A3/B4 and A4 timing belt tools Injection pump head how-to
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Old November 8th, 2006, 15:12   #57
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CHJ is chinahanji.com
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Last edited by BKmetz; March 3rd, 2012 at 19:39. Reason: C.R.A.P. link removed
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Old November 8th, 2006, 15:16   #58
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P2B, Yeah, I went on google spree and found pretty much the same thing. Chinese made.
Ray
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Ultimate cup holder for B4's Dimensions for A3/B4 and A4 timing belt tools Injection pump head how-to
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Old November 8th, 2006, 19:11   #59
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I wonder if these work better than the $25 B4 foglights...
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Old November 8th, 2006, 19:27   #60
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Hey, those 25.00 dollar fog lights work great until you turn them on!
Ray
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