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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 December 29th, 2011, 18:54   #16
vankei
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Figured as much, but thanks for the heads up. Sounds like a job for the morning.
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Old January 7th, 2012, 16:40   #17
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I did a big no-no today. Insead of using this great resource, I plowed ahead and did it my way. Shame on me!!!

I am having an annoying vacuum pump gasket leak that I thought was coming from the "P" shaped gasket. I have replaced two of these on this car, and have always had an oil seepage there. Frusterated about the leak the last time I used some Ultra Grey RTV on the vac pump to head gasket. I went sparingly on the RTV and ended up having the leak come back but seemingly worse this time. Long ago I had disassembled the vac pump and had seen that other gasket between the two halves, and not having a replacement gasket for it, I put some RTV on it too. Now that my leak is back, I once again removed the two vacuum pump sections, cleaned the area and applied some fresh RTV to it. I wish I would have seen this information in this thread before I applied the RTV again. I guess in the future I will use my old ALH oil filter O ring and replace that vac pump gasket with it instead. I may have to look at work to see if I have a spare large viton O ring to replace it with next time. Thanks for the valuable information on this fix guys!
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Old January 8th, 2012, 04:54   #18
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I am positive that even if I use an old O ring from the oil filter housing that has 10K on it, that once it is installed into the vacuum pump and undisturbed that it should have a very long life correct? Any updates from anyone as to the longevity of this fix(although it looks like a perfect solution )?
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2002 VW Jetta TDI 5-speed(completed 01M-5-speed swap at 155K miles) 60+ MPG City.
Experimenting with the "Hybrid" 205 Deg F T-stat:
http://forums.tdiclub.com/showthread.php?t=306799&page=4
Now have Nokian Entyre Low RR tires!
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Old January 8th, 2012, 14:22   #19
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The ALH ring is too thick. You'll have to get a BRM ring or equivalent 74x3mm
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Old January 9th, 2012, 16:40   #20
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Quote:
Originally Posted by runonbeer View Post
The ALH ring is too thick. You'll have to get a BRM ring or equivalent 74x3mm
Thanks for the clarification on the ALH oil filter O ring being too thick!

Question


Looks like I can get a viton O ring that is 75x3mm- will that most likely work?

They also have a Buna N "O" ring that is 74x3, but I would prefer the Viton if at all possible.
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2002 VW Jetta TDI 5-speed(completed 01M-5-speed swap at 155K miles) 60+ MPG City.
Experimenting with the "Hybrid" 205 Deg F T-stat:
http://forums.tdiclub.com/showthread.php?t=306799&page=4
Now have Nokian Entyre Low RR tires!
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Old January 9th, 2012, 17:04   #21
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I don't know. never tried a 75.
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Old January 10th, 2012, 18:14   #22
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Ok, thanks for the info. I went ahead and ordered the Buna N 74x3mm "O" rings like you suggested. The Buna N will be perfect for the temperatures involved and the engine oil. I think they come 25 per pack, but they are relatively inexpensive. Looks like I'll have plenty to give for gifts to my local TDI friends here After I'm through none of us will have vacuum pump oil leaks again!
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2002 VW Jetta TDI 5-speed(completed 01M-5-speed swap at 155K miles) 60+ MPG City.
Experimenting with the "Hybrid" 205 Deg F T-stat:
http://forums.tdiclub.com/showthread.php?t=306799&page=4
Now have Nokian Entyre Low RR tires!

Last edited by josh8loop; January 14th, 2012 at 17:55.
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Old January 14th, 2012, 17:58   #23
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Just replaced it last night, and took some DIY photos. So far so good, but it's too early to call it a success though. The last time I had it apart(a week ago) I took out that seal and coated it with Ultra Grey RTV since I didn't have a replacement at that time. I figured, what the heck, I may as well try something! Well, as it turns out, certain parts of the vacuum pump have a slight bit of oil pressure, and the RTV didn't stand a chance. It only took a few days for me to start notice it leaking again, so in a few more days I will be able to know whether or not it was a success or not.

Sure glad I found the info here on the replacement "O" ring. It fit perfectly with a slight bit of stretching before I formed it into place. So I can confirm, the 74x3mm was perfect as RunOnBeer suggested. I will post in a week or so as to the results. I fully expect that they will be positive
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2002 VW Jetta TDI 5-speed(completed 01M-5-speed swap at 155K miles) 60+ MPG City.
Experimenting with the "Hybrid" 205 Deg F T-stat:
http://forums.tdiclub.com/showthread.php?t=306799&page=4
Now have Nokian Entyre Low RR tires!

Last edited by josh8loop; January 27th, 2012 at 10:48.
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Old January 27th, 2012, 10:48   #24
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Well, It's been a while with the new McMaster Carr purchased 74x3mm O ring that I installed on the vacuum pump. It still leaks on me! I've been trying to get this issue fixed for the last year and a half or so. In fact, ever since I got the car at 105K miles it was leaking. I inspected the new O ring I put in there for any damamge that I could have done during the installation. No damage was found, but I did notice the O ring seemed a bit thin relative to the O ring land area and it definately molded into a square shape over the short amount of time it was installed. I measured the new O rings I purchased from McMaster, and they measure 2.85mm thick instead of the 3mm they are suposed to be. Must be 3mm nominal thickness I guess.

I'm not 100% sure where the oil is coming from, but from what I can tell it seems to be coming from between the two halves of the vac pump. I figured I would use some 1500 grit wet or dry sandpaper and clean up the vac pump body sealing surfaces between the two halves and look for any high spots that may be giving me trouble. I put the sandpaper on the granite kitchen countertop so I got a very flat end result. I probably removed .001-.002 of material. Doing this step should at least remove that from the leak equation. So far my list of possible leak points are:

Valve Cover(that is UltraGrey RTVed on)
Undersized(2.85mm thick) replacement vac pump body O ring
Slight step between the cam bearing cap and the aluminum head


We will have to wait and see if this latest effort was successful. I would definately recommend folks who replace the vac pump body O ring make sure they get a full 3mm thick O ring-It does make a difference!
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2002 VW Jetta TDI 5-speed(completed 01M-5-speed swap at 155K miles) 60+ MPG City.
Experimenting with the "Hybrid" 205 Deg F T-stat:
http://forums.tdiclub.com/showthread.php?t=306799&page=4
Now have Nokian Entyre Low RR tires!

Last edited by josh8loop; June 4th, 2012 at 09:23. Reason: spelling
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Old January 27th, 2012, 16:51   #25
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I ended up finding a 75x3.4mm O ring from work that is Viton. If the work I did last night doesn't work, then ill try this one. It looks a little thick however.
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2002 VW Jetta TDI 5-speed(completed 01M-5-speed swap at 155K miles) 60+ MPG City.
Experimenting with the "Hybrid" 205 Deg F T-stat:
http://forums.tdiclub.com/showthread.php?t=306799&page=4
Now have Nokian Entyre Low RR tires!
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Old January 28th, 2012, 11:18   #26
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Make sure the pump rotates by hand with the thicker seal installed before you put it on the engine.
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Old January 28th, 2012, 15:12   #27
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Well, unfortunately the work I did the other night with the new O ring, and lightly sanding down the sealing surfaces didn't work-It's still seeping a bit of oil already. Eventually I will try the thicker Viton O ring and see what happens. Thanks RunOnBeer for the advice about making sure it turns by hand with the new thicker O ring installed-I will make sure I do that. I'll keep yall posted on progress!
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2002 VW Jetta TDI 5-speed(completed 01M-5-speed swap at 155K miles) 60+ MPG City.
Experimenting with the "Hybrid" 205 Deg F T-stat:
http://forums.tdiclub.com/showthread.php?t=306799&page=4
Now have Nokian Entyre Low RR tires!
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Old January 28th, 2012, 16:06   #28
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Hope your work isn't in vane...

Does anyone have a VW part number for a BRM oil filter "O" ring?

Yuri
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Old February 1st, 2012, 11:10   #29
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Quote:
Originally Posted by ymz View Post
Hope your work isn't in vane...

Does anyone have a VW part number for a BRM oil filter "O" ring?

Yuri
OE Part number is 071115444
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Old April 10th, 2012, 04:29   #30
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Great Thread !! Thanks everyone for the helpful tips and " RunOnBeer" for great pictures & instructions. After Growler & I replaced my engine earlier this year, we noticed a small leak. After several attempts to figure it out, including using another vac pump, Growler found this thread.

Well, last night I took my pump off, followed the helpful tips from this tread and installed a BRM filter O-ring in place of the " Flatten " O-ring.

Replacement O-ring fits like it belonged there and appeared to have enough to properly seal it up.

Too early to tell but I have my fingers crossed this works as we have been scratching our heads for some time now trying to pin this one down.

I took pictures and will add any that may help upon review, one thing I noticed on my pump which I didn't catch until I had did the rebuild and had installed it back on my car was the vac hose connection on the pump was very loose and turned. The loaner Growler provided me didn't so I decided to take it off, rebuild Growlers and installed it.

Time will tell, stay tuned and again thanks for all the tips everyone, great support, makes one feel proud to be part of a great club. Hope to meet some of you at TDI Fest.
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