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TDI 101 Got a simple/basic TDI question? Are you a newbie (new to the forums). Feel free to post your question here.

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Old July 8th, 2010, 18:43   #1
runonbeer
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Default How to video: On car VE injection pump seal replacement video

This is the one that we have been waiting for. It shows, in detail, how to replace the three most-likely-to-be-leaking seals on an ALH injection pump: the top cover, quantity adjuster & head seal. It is also applicable to the pumps on the A3/B4 cars.

It is long, but some will appreciate this. There are seven parts. Watch all 7 before beginning the repair to ensure you have all tools and equippment on hand. VCDS required!

Grab your T-30 and watch this:

http://www.youtube.com/watch?v=VR44StvcXms

Last edited by runonbeer; December 16th, 2010 at 19:01.
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Old July 8th, 2010, 18:44   #2
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Old July 8th, 2010, 21:23   #3
chlavenka
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I see many posts about the three main injection pump seal replacements (head, top, and middle). My question is about the other side, or timing belt/sprocket side. Is there a replaceable seal here where it mounts onto the bracket, and if so, is it included in one of the seal kits for sale?
I've looked with a light and mirror all around and my pump really seems to have a small, slow leak emanating from all around this mount.
-2002 Golf TDI, ALH
-Carl
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Old July 8th, 2010, 22:16   #4
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that's great
it's should be sticky
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Old July 9th, 2010, 01:03   #5
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Great stuff guys. Definitely should be either a sticky or linked in the How-To thread.
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Old July 9th, 2010, 04:01   #6
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this will help a lot of people thanks
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Old July 10th, 2010, 12:23   #7
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Thanks alot for the video Runonbeer!
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Old July 10th, 2010, 19:32   #8
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Quote:
Originally Posted by chlavenka View Post
I see many posts about the three main injection pump seal replacements (head, top, and middle). My question is about the other side, or timing belt/sprocket side. Is there a replaceable seal here where it mounts onto the bracket, and if so, is it included in one of the seal kits for sale?
I've looked with a light and mirror all around and my pump really seems to have a small, slow leak emanating from all around this mount.
-2002 Golf TDI, ALH
-Carl
The front seal isn't a job you can do without taking it to a pump shop. I requires removing the hub and the hub isn't keyed and nearly impossible to put back in the correct position. So if the front seal is leaking you will need a complete pump rebuild by dfis in Portland.
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Old December 16th, 2010, 14:50   #9
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Excellent how to! I just changed my seals, it took me several attempts. Let me explain what I found out, it may help someone else. I bought two kits $12.95 ea just in case I messed up. I also went to a local O ring shop and bought three Viton seals. The first seal I scuffed so I did the job again. Broke the second seal somehow. The third seal I really took my time and used the utmost care. after assembly I still could not get the pump to prime (using the method in the video) so I took out the seal thinking I must have damaged it. It was perfect so I reinstalled it and changed the cover and adjuster plate gaskets again. Still would not prime. Thought the vitons must be the wrong size so I replaced with the Bosch O ring. Still would not prime. Then I thought that I would remove the adjuster plate and fill the pump with diesel. It worked! The pump took the prime, bled the injectors, set IQ and now I am very happy. One point I wish to reiterate, do not take all of the fuel out of the pump. If you do it may be extremely hard to prime.
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Old December 16th, 2010, 19:00   #10
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When you back the pump head out of the body to replace the seal, you will "remove all of the fuel from the pump." It's unavoidable. I'm not quite sure what problem you were encountering there.

Congratulations and thanks for the bump!
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Old December 17th, 2010, 20:39   #11
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Very nice vid ! ! ! Great attention to detail.

Is it possible and / or advisable to replace the quantity adjuster?

Mine has the flashing glow plug light and has thrown a code indicating QA out of range. I have messed with the adjustment but no change. She surges at idle and the fuel economy has dropped.

If replaceable, where might I purchase one?

Thanks,

JT
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Old December 19th, 2010, 06:05   #12
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Quote:
Originally Posted by Jerry_T View Post
Very nice vid ! ! ! Great attention to detail.

Is it possible and / or advisable to replace the quantity adjuster?

Mine has the flashing glow plug light and has thrown a code indicating QA out of range. I have messed with the adjustment but no change. She surges at idle and the fuel economy has dropped.

If replaceable, where might I purchase one?

Thanks,

JT
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Old January 24th, 2011, 16:01   #13
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GREAT VIDEO!!
I just did my seal with the video and it was very detailed oriented. Follow it to a "T" and you won't go wrong. Runonbeer advises on another post to replace the head plug seal, excellent idea, but you will have to fabricate a specific tool to remove the head plug which is in the middle of the head between the injector outlets.
Mine was leaking there also. 15/16" 6 point socket with 3 sides rounded out.
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Old January 24th, 2011, 20:16   #14
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High five!
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Old February 2nd, 2011, 07:29   #15
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Quote:
Originally Posted by mtbr297 View Post
The front seal isn't a job you can do without taking it to a pump shop. I requires removing the hub and the hub isn't keyed and nearly impossible to put back in the correct position. So if the front seal is leaking you will need a complete pump rebuild by dfis in Portland.
Actually you can replace front seal easily if you know how & pump is still in good condition, doesnt have too much wear on housing from rollers. I have done lot of them for past 2 years with great success, the first one did on customers car and he been driving for 2 years now no issues.
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