Injection Pump Head o-ring Replacement Frustrations...

In attempting to replace the o-ring that seals the injection pump head one of the torx screws that holds the head to the body stripped. Not the threads, but the head of the torx screw itself.

It's the one in the following picture:
http://www.dieselgeek.com/images/DCP_4939.JPG

I know I can go buy a Craftsman bolt-out tool set to get the bolt removed, but I'll have to find a source for a new one. Does anyone have any idea if I could get a replacement from a dealer, or if getting a new one is going to be an extremely difficult and convoluted process? Any idea on a part number for that silver torx screw.

i actually 5 days ago did same job and find allen head bolt at car quest im in san diego no problem size 6mm-50mm lengh and 1.0 thered

Any good hardware store with metric bolt selection should have an allen head bolt that will replace that.

That's amazing news, thanks guys. I really don't understand why they would bother using the torx bits on there. Even though I bought a good quality craftsman set of torx bits I felt like the T-30 was really loose in there and was worried that they might strip...

torx would transmit higher torque then Allen.

The saga continues....

Received my "bolt-out" set in the mail today from my parents' house. Lo and behold, it contains a #2 and a #4 but not a #3 which is exactly the one I need. #2 is too small, and #4 is too large...... Grrrrr....

can't you just drill the head off, remove the lid, and unscrew?

DPM said:

can't you just drill the head off, remove the lid, and unscrew?

Click to expand...

Nope. If you actually remove the head of the pump then you have to rebuild the internals, which is a job for a Bosh pump shop, not a home mechanic.

is the pump off the car?

if you place the pump vertically (with the head up), you can remove the pump head. there are three rollers below that need to be aligned. There are also two springs, and two shafts, fairly obvious the way it comes together.

have you tried a 12 point 8mm or 9mm socket, hammer it on the bolt?

if it's still on the car, make sure you've got the pump head seal all the way on the pump, it tends to catch on the bottom... then it will cut the seal, and you're back to square 1.

alphaseinor said:

is the pump off the car?

if you place the pump vertically (with the head up), you can remove the pump head. there are three rollers below that need to be aligned. There are also two springs, and two shafts, fairly obvious the way it comes together.

have you tried a 12 point 8mm or 9mm socket, hammer it on the bolt?

if it's still on the car, make sure you've got the pump head seal all the way on the pump, it tends to catch on the bottom... then it will cut the seal, and you're back to square 1.

Click to expand...

Pump is still in car.

I finally got the job done today. The only issue I'm still having is that 2 of the injector lines have slow leaks at the injectors even though I've loosened and re tightened them a few times.