2000 ALH: IP still leaking after replacing head seal

[mcm]

Replaced the IP head seal with the dieselgeek kit (black viton).. followed instructions here. I am fair ****s sure it was not pinched, split, snapped, or over-stretched (in fact it did not seem very stressed pulling it over the pump head.)

Sadly the IP is still leaking. Engine idles rough as guts. The leak is fairly fast... reminds me of one of those low GPM drip irrigation systems...

I've attached pictures showing where the fuel is dripping from, it's hard to tell but it LOOKs like its coming out from the lower/front pump head retaining bolt (the long black one at the bottom.) Either that or the injector fitting right next to it? Do these have seals between fitting and iron pump head?

This photo is using a mirror:

Is this indicative of a bad seal change? or is there another seal I need to replace? In the seal kit I received, I have literally 12 or 15 additional seals I did not use (I only replaced those I could figure out w/o taking the injector pump off the car.)

Is this possibly the #4 cyl delivery valve/holder leaking? e.g., #4/5 on this diagram:

Thoughts?

 

[whitedog]

The big, triangle shaped plug in the center of the head. In that last picture, there is a long, hex headed plug in the center, and it screws into the big, triangle shaped plug. You can take a 15/16, six point socket and grind out every other flat until it fits. The O-ring is in the kit.

 

[mcm]

The big, triangle shaped plug in the center of the head. In that last picture, there is a long, hex headed plug in the center, and it screws into the big, triangle shaped plug. You can take a 15/16, six point socket and grind out every other flat until it fits. The O-ring is in the kit.

Taking a stab at it now...

 

[mcm]

the big, triangle shaped plug in the center of the head. In that last picture, there is a long, hex headed plug in the center, and it screws into the big, triangle shaped plug. You can take a 15/16, six point socket and grind out every other flat until it fits. The o-ring is in the kit.

you sir, are a ****ing legend. :d

 

[whitedog]

Nope. I just repeat what others have learned and shared. Credit goes to that beer dude, runonbeer.

 

[runonbeer]

The most super secret page on the dieselgeek website:

http://www.dieselgeek.com/product_p/pmp-24mmsocket.htm

If you would like to buy one of these sockets outright along with a custom top cover triangle bit you can email MikeG:

mgh151721@sbcglobal.net

The seal for the plug is in your leftover pile from the Bosch kit. It's black whereas the crispy leaky one you're going to get out of the pump is red.

 

[mcm]

I just took a die grinder to a deep 15/16 socket.. Did the trick.

The plug made a hell of a squeeking sound coming out... Then i saw it was the old seal being wrapped around its threads... Big circumferencial split.

Popped the replacement seal in and buttoned up.

I did, for good measure, also pull the lower delivery valve holder and replaced the copper crush washer.

All is leak free and running great

 

[mr_mufy]

hi guys.
My tdi pump has the same leak at this one.
But i think that it's on the delivery valve holder...
How can i stop the leak on the bolt?
- Can i remove the line and the screw without any wary on the inside of the ip?

 

[KLXD]

hi guys.
My tdi pump has the same leak at this one.
But i think that it's on the delivery valve holder...
How can i stop the leak on the bolt?
- Can i remove the line and the screw without any wary on the inside of the ip?

What bolt, what screw? If you mean the delivery valve holder, nothing is under it except the copper gasket. #5 in the pic is screwed into #4.

 

[mr_mufy]

What screw? If you mean the delivery valve holder, nothing is under it except the copper gasket.

hi tks for the awnser.

The screw it's the delivery valve holder i think.

the leak it's in the thread of the delivery valve.

All i have to do it's screw a lit better to stop the leak our remove the delivery valve?

 

[Dizzy.618]

Hi Guys,
Thanks to one and all.
You guy do ROCK. Your help is far beyond belief.
Waiting on Mike for a price on the socket.
The time to sacrafise a socket when it will be wednesday before I can
put a wrench on it makes ordering it simpler.
I'll keep you posted.
cudo's to all.
Dave

 

[Jettascuba]

You can also remove two delivery valves and use an open ended spanner to remove this bolt - 11/16 I think.

 

[Jettascuba]

If IP is leaking at delivery valve, make sure it is tight - 45Nm on new washers I think.

 

[Dizzy.618]

Update
The sockets came in and I was right. I could have made the socket BUT the amount of time and the precise fit job Mike G. did was worth the extra bucks this time. I was done in a fraction of the time.
VCDS does not like my Vag-Com cable. Too many communication errors to be reliable.
I almost registered VCDS lite but it said, if it does not read the modules now ,it won't when its registered either.
I may hammer it later any way, seems rich and has plenty of power. I think my 41 mpg is gone. Next have to tackle EGR intermitant reading. And ABS light . Running out of time has to be inspected this month.
Thanks Dave

 

[mr_mufy]

Hi guys.

Yestarday i remove my 4 delivery valve to stop the leak.

But i have a dout about the torque.

The delivery valve needs to be a full torque or needs some space internal to the string works?

Becausa today my car doesn't start... I lose my battery traing to start.

What can be wrong on the delivery valve?

 

[whitedog]

Did you bleed the air out of the pump?

 

[mr_mufy]

Did you bleed the air out of the pump?

yes I did.
But it was from the tubes of the injectors ... What may not have been the best.

- But the car picked up and works already, though I imagine he was run less.
Today to go to work, did not get ... He did the same as yesterday.

tightness in the delivery valves, is not to give more grip?

 

[mr_mufy]

I guys.

Finally i put my car to start again.
- Lack of diesel on the IP.

I don't now whay, but the transparent tube becames empty.

I had to purge again the diesel and start evething ok, but i find out what can be my problem.

The tube that connects to the inject is damaged, so the can fild by there no?

I replace the tube, stand by the car by about 2hours and try the start and here we go again, evething it's ok.

Can i pull of joy???

- The leak on my car it's on the head, were it's the strang plug.

Can i remove the plug and do the isolation our even replace the o ring without do any mess on the interior of the pump?

 

[KLXD]

If you mean the three sided plug in the center, it can be removed without anything falling out.

You will have to bleed it again.

 

[mr_mufy]

If you mean the three sided plug in the center, it can be removed without anything falling out.

You will have to bleed it again.

Yes, it.s that wear plug of 3 sides.

And whatabout the 4 delivery valves?
The screw ITA all the end our i have to stop screw ar some point before i cant screw more?

 

[KLXD]

The delivery valves can be removed without anything falling out also. There is a solid copper gasket under them.

The screw ITA all the end our i have to stop screw ar some point before i cant screw more?

I'm not sure what you are asking. The screw in the center of the three sided plug also has a copper gasket. It does not adjust anything. Just a plug. It should be tight but I do not know the torque.

 

[mr_mufy]

The delivery valves can be removed without anything falling out also. There is a solid copper gasket under them.



I'm not sure what you are asking. The screw in the center of the three sided plug also has a copper gasket. It does not adjust anything. Just a plug. It should be tight but I do not know the torque.

Hi guys, TKS for ur help, it,s very helpfull.

OK, what i want to know is;

In the delivery valves, i remove them to stop the leaking.
Now i put it baço, and no leal, só its OK, but the car hás some isue, because it lak of some power...

Só how tight should the delivery valves be?
Till to the end? Our
i need to stop screw some point?

 

[mr_mufy]

hi guys

can you tell me the binary of screw (nm) for the fuel delivery valves?