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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 August 26th, 2005, 17:16   #1
TDI001
Newbie
 
Join Date: Mar 2005
Fuel Economy: 43/47/58
Default Help ! Injector Pump Seal Leaks

Hi. I've been noticing some diesel seeping through between the top cover of my injector pump on a 96 TDI passat. The cover is held down with 3 torx bits and hex bolt. My car runs fine with no smoke despite the loss of fuel.
1.Can I just replace the seal myself?
2.Where can I buy the seal? Can I use these for a quick fix?
Thanks for any comment.
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Old August 26th, 2005, 17:51   #2
TDI001
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Join Date: Mar 2005
Fuel Economy: 43/47/58
Default a pic showing where it leaks

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Old August 26th, 2005, 18:56   #3
latitude500
Veteran Member
 
Join Date: Jul 2004
Location: Austin Tx, USA
Fuel Economy: 51/45/39
Default a pic showing where it leaks

I did a search and found this.

http://forums.tdiclub.com/showflat.php?C...rue#Post1030985
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Old August 26th, 2005, 18:59   #4
runonbeer
Maintenance EnthusiastVendor
 
Join Date: Apr 2002
Location: Austin, TX
Fuel Economy: amazing/excellent/still pretty good
Default a pic showing where it leaks

That ain't no hex head boy!

required tool

try a search for "pump leak fix" or the like. its been done and documented before.
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Old August 26th, 2005, 19:27   #5
whitedog
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Join Date: Jul 2004
Location: Bend, Or.
Fuel Economy: 42 Jetta, 47 Beetle
Default a pic showing where it leaks

Quote:
That ain't no hex head boy!

required tool

try a search for "pump leak fix" or the like. its been done and documented before.
And be sure to wear eye protection like the Lawyer label says on that tool.
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Old August 26th, 2005, 19:40   #6
Rickstah
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Join Date: Feb 2002
Location: Yukon, Oklahoma
Fuel Economy: 51/45/41
Default a pic showing where it leaks

Quote:
That ain't no hex head boy!

required tool

try a search for "pump leak fix" or the like. its been done and documented before.

HEY SPEAKING OF BOY!!!! How's it goin, boy??? long time not talk...hope all is well for you, Robbie.
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Old August 26th, 2005, 22:12   #7
runonbeer
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Join Date: Apr 2002
Location: Austin, TX
Fuel Economy: amazing/excellent/still pretty good
Default a pic showing where it leaks

All's well. Tell your wife I just got myself a fiddle. as a matter of fact 5 minutes ago I was running through the Gmajor scale. I suck!
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Old August 27th, 2005, 08:22   #8
whitedog
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Join Date: Jul 2004
Location: Bend, Or.
Fuel Economy: 42 Jetta, 47 Beetle
Default Help ! Injector Pump Seal Leaks

Something that no one answered:

Those sealants would not fix your leak unless you opened up the top. smearing it on the outside may cover it for a bit, but the fuel will still be leaking past the joint. I would not put it in place of or in addition to the seal that is there. With that kind of stuff, the excess will squeeze out from the joint and get into the inside of the pump. It won't become a wear material since it is soft, but it does have the ability to plug things and, depending on which one you use, it may cause problems with the fuel.

Better to just drop the dime and get a new seal.
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Old August 27th, 2005, 11:04   #9
Audi5000TDI
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Join Date: Jul 2005
Location: CA, Good old USA
Fuel Economy: 44,51, 59.08 mpg
Default Re: Help ! Injector Pump Seal Leaks

Newbie,

1st things first.

Forget about owning a diesel if you are going to do things half assed or do "patch" jobs. The level of pressure and the tolerances make injector pumps quite unforgiving of shade tree mechanic tricks.

Secondly, if you don't have the wherewithall to handle a red dipstick tube top breaking while doing your own oil change, and figuring out how to handle that, forget about even turning a wrench on your injector pump. Get someone that's a mechanic to do it for you, I doubt you have the skill sets, especially when you can't even notice the special bolt head on your injector pump.



Find a good TDI mechanic in your area and don't ever piss him off, because you are going to need his services regularly with that 1996 Passat.

If you still feel up to tackling it, read this carefully and read it a full 5 times before you attempt it.

http://forums.tdiclub.com/showflat.p...art=2&amp;vc=1


If that doesn't work, try this, it's on page of of this post.

http://forums.tdiclub.com/showflat.p...;page=0#713742

and if that doesn't work, go do a search under Audi5000td and then search for a post dated June 02, 2005, around 7:20pm. Then start at the beginning of the thread and read it all the way through, several times.
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Old August 27th, 2005, 15:52   #10
Audi5000TDI
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Location: CA, Good old USA
Fuel Economy: 44,51, 59.08 mpg
Default Re: Help ! Injector Pump Seal Leaks

Moderator,

Could you please make a"sticky" out of this "how to" in this column or the other one?

http://forums.tdiclub.com/showflat.p...;page=0#713742
Thanks!
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Old August 27th, 2005, 17:10   #11
whitedog
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Join Date: Jul 2004
Location: Bend, Or.
Fuel Economy: 42 Jetta, 47 Beetle
Default Re: Help ! Injector Pump Seal Leaks

Quote:
Moderator,

Could you please make a"sticky" out of this "how to" in this column or the other one?

http://forums.tdiclub.com/showflat.p...art=2&amp;vc=1

Thanks!
Either I suck, or it's a really short topic:

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Old August 29th, 2005, 06:44   #12
BKmetz
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Join Date: Sep 1997
Location: Illinois
Fuel Economy: 45 MPG
Default Re: Help ! Injector Pump Seal Leaks

Quote:
Moderator, can we make this post a "Sticky" since it comes up so frequently?
Done.
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Old September 1st, 2005, 18:21   #13
BKmetz
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Join Date: Sep 1997
Location: Illinois
Fuel Economy: 45 MPG
Default a pic showing where it leaks

Quote:

Here are the VW and Bosch part numbers for anyone else who has to change out the TOP fuel pump cover gasket/seal.

Last edited by BKmetz; April 30th, 2006 at 17:52.
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Old November 2nd, 2005, 19:13   #14
jsanch
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Join Date: Oct 2005
Location: South Texas
TDI(s): 1996 Passat
Default Re: a pic showing where it leaks

Here's a kit I got but have not installed it yet

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Old November 8th, 2005, 06:31   #15
wooddashman
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Join Date: Oct 2005
Location: fl
Default Re: a pic showing where it leaks

Any one have a VW part number for the lower seal?
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