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VW MKIV-A4 TDIs (VE and PD) This is a general discussion about A4/MkIV Jetta (99.5-~2005), Golf(99.5-2006), and New Beetle(98-2006). Both VE and PD engines are covered here.

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Old September 30th, 2011, 03:47   #1
redline808
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Default 2002 injection pump leaking diesel?

i just noticed a diesel fuel leak on my injection pump, it seems to be coming from the bottom section of the injection pump, i only say that because i didn't notice any wetness coming from the top half. but i did not bother to check the back side of the injection pump? car runs fine. any thoughts. i drew an arrow pointing at the fuel drip forming.

thanks.

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Old September 30th, 2011, 04:02   #2
Strykeviper
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Fuel Economy: '01 33-39; '00 40-53
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Dry off the pump and then start the car and look for where the leak is coming from. Check the two upper seals and the o-ring at the pump head, these are common places for fuel to leak. If it comes from the top, it is easy to change those gaskets but you will need a special bit to remove the security screw. If it comes from the o-ring at the front, contact a guru or do a lot of research before attempting to change the seal. Otherwise you may have to replace the injection pump if you mess up with that seal. Don't ask how I know
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Old September 30th, 2011, 11:58   #3
horsieclatter
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what he said^^^^^
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Old October 1st, 2011, 00:37   #4
Redneck Truck
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I'd check hose and line fittings too.
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Old October 1st, 2011, 05:49   #5
MrSafety
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In finding such leaks, I find it useful to first spray the entire pump with a water soluable degreaser ["Simple Green"],
then wash off with water... and finally dry it off with compressed air or a strong leaf blower!
After the above your chances of seeing the source of the leak are much better when you start up to look again!.
Also a blue paper towel that is typically used in shops is good to "dab" wherever you suspect a leak...
as these towels turn dark when wetted!
It's probably a good idea to invest in a gasket/seal kit for your IP.
These run about $25.00!
Remember, the smaller-the-leak, the harder-it-is-to-find!
Regards,
Sam
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Working on way for DIYers to more fully FLUSH 01M trans as well as check/"top-off" the O1M Fluid Level.
Perform diesel purge without ingesting troublesome air !

Last edited by MrSafety; October 1st, 2011 at 05:52. Reason: [edit] in Bright Blue!
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Old October 2nd, 2011, 10:50   #6
runonbeer
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Classic pump head seal leak (probably in addition to other leaks). I can see it puddled up in the accessory bracket bolt reccess.

Check out the link in my signature.
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Old October 2nd, 2011, 11:04   #7
runonbeer
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I would personally avoid using simple green on the aluminum injection pump and all other surrounding aluminum components.

I use permatex earth soap with fantastic results.
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Old October 2nd, 2011, 13:14   #8
TDI_bubble
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Since the majority of the main case looks dry, its most likely the head seal oring where the cast aluminum/steel are at. Very common, I would replace the top seals while your at it, and reset the IQ/timing in one shot. If you have vagcom that is.
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Old October 2nd, 2011, 13:17   #9
MrSafety
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Quote:
Originally Posted by runonbeer View Post
I would personally avoid using simple green on the aluminum injection pump and all other surrounding aluminum components.
I use permatex...
Is Simple Green corrosive to aluminum?
Sam
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Other Projects
: Safe Intake Cleanout / IP-QA Craniotomy /
Working on way for DIYers to more fully FLUSH 01M trans as well as check/"top-off" the O1M Fluid Level.
Perform diesel purge without ingesting troublesome air !
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Old October 2nd, 2011, 18:58   #10
TDI_bubble
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http://www.simplegreen.com/solutions...query=aluminum

For regular things, sure. It takes corrosion off, but that corrosion is aluminum's corrosion.
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Old October 2nd, 2011, 21:15   #11
MrSafety
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Quote:
Originally Posted by TDI_bubble View Post
http://www.simplegreen.com/solutions...query=aluminum
For regular things, sure. It takes corrosion off, but that corrosion is aluminum's corrosion.
Thanks for information on the citric-based Simple Green solvent... and it makes good precautionary sense where it says:
" Therefore, contact times for unprotected or unpainted aluminum surfaces should be kept as brief as the job will allow -
never for more than 10 minutes."
We have found in general that it was never necessary to let Simple Green soak very long...
and of course it makes sense that one should take special caution on thin aluminum plate on the skin of aircraft
where you probably do not want to take off the natural protective layer of corrosion that forms on aluminum !
Regards,
Sam Ross
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Son's 2002 Jetta TDI 01M / My '81 Rabbit "Caddy" project / My '80 240D MB...
Other Projects
: Safe Intake Cleanout / IP-QA Craniotomy /
Working on way for DIYers to more fully FLUSH 01M trans as well as check/"top-off" the O1M Fluid Level.
Perform diesel purge without ingesting troublesome air !
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Old April 23rd, 2012, 02:42   #12
redline808
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just an update, i have not replaced the seals in my ip yet. i have been slacking, mostly because it stopped leaking the day after i started driving on svo. now in diesel or svo, perfectly dry. i really should change the seals, my thoughts now are the seals have swelled up because of the svo and might be breaking down and being fed into my injectors?
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Old April 23rd, 2012, 16:59   #13
MrSafety
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Default ... What is SVO...

Quote:
Originally Posted by redline808 View Post
just an update, i have not replaced the seals in my ip yet. i have been slacking, mostly because it stopped leaking the day after i started driving on svo. now in diesel or svo, perfectly dry. i really should change the seals, my thoughts now are the seals have swelled up because of the svo and might be breaking down and being fed into my injectors?
What is "SVO"... some kind of alternative fuel?
Sam
__________________
Son's 2002 Jetta TDI 01M / My '81 Rabbit "Caddy" project / My '80 240D MB...
Other Projects
: Safe Intake Cleanout / IP-QA Craniotomy /
Working on way for DIYers to more fully FLUSH 01M trans as well as check/"top-off" the O1M Fluid Level.
Perform diesel purge without ingesting troublesome air !
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Old March 6th, 2014, 11:35   #14
Dieselnoob
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Default Bump

Will the pump head leaking be to the extreme that it can cause the pump to loose its prime, causing a no start? I ask because I believe this is what's happening with mine. I'll be getting the new seal kit next week, but wanted to know if I'm headed in the right direction.
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Old March 6th, 2014, 11:47   #15
Ski in NC
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Yep, if fuel leaks out while running, air can leak in while shut down. But leak would have to be pretty bad for that to happen. Suspect filter therm tee or shaft seal first.

My pump was leaking similar to OP's. It was hard to determine exactly the leak location, but there was wetness under the top cover/QA. I got the seal kit and decided to just do the two top seals first, as they are easier. That cured the leak. Head seal is apparently still holding.
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