Cam plate and roller failure

adriel1440

New member
Joined
Jan 1, 2025
Location
USA
TDI
1999 Volkswagen Jetta TDI ALH
I bought this 1999 MK4 Jetta a few weeks ago. It made it home, barely. The car wouldn’t accelerate above 2000rpm. The seller told me it was a leaking injection pump.

OK, I’ll take it!

$700 later, I am a proud owner of an ALH Volkswagen.

I decided to try resealing the pump myself. Wasn’t too hard to find the right seals and tools online. Now, I wanted to do a deep dive into the pump and really tear it apart. I found out the cam plate and rollers had chunks missing off of them. The pump shaft also had a groove cut out right where the seal rests.

I found a DE110 cam plate online easily. However, the other two parts are showing to be much more difficult to source. Where could I find rollers and a shaft? Is it a better idea just to get a remanned pump?

My last question is, has anyone dealt with this before? I don’t think I’ve ever seen anything like this.
 

zslnk

Veteran Member
Joined
Sep 4, 2006
Location
ON, CANADA
TDI
E320 CDI, 3rd gen Cummins 2500, ALH Sedan
If the rollers look like that I wouldn't be putting parts money into that pump. Find a used pump for little money if you can.

It looks like it got water in it.
 

Genesis

Top Post Dawg
Joined
Feb 26, 2003
Location
Sevier County TN
TDI
'03 Jetta Wagon
Seconded on that. Find one from a pick-n-pull. Do not buy one on FleaBay as odds are high it will be from you-know-who and you'll be lucky if its not in worse shape than what you have now.
 

KrashDH

Top Post Dawg
Joined
Dec 22, 2013
Location
Washington
TDI
2002 Golf
DFIS can get all the new OEM pump parts. Look into them. It's how I sourced a few pump parts I needed. Be very meticulous with your rebuild, that's the best advice I can give. I have a DIY on the forum too
 

agent_jwa

Well-known member
Joined
Feb 9, 2024
Location
WI
TDI
02 Golf
If you need hard to find parts, the guys at diesel forward/alliant power have access to the entire Bosch catalog. They ordered me individual pump parts and they were surprisingly cheap. They told me that they were the only full distributor for Bosch in the US.
 

jmodge

Top Post Dawg
Joined
Jun 18, 2015
Location
Greenville, MI the winter water wonderland
TDI
More than I need, less than I want
If you need hard to find parts, the guys at diesel forward/alliant power have access to the entire Bosch catalog. They ordered me individual pump parts and they were surprisingly cheap. They told me that they were the only full distributor for Bosch in the US.
That's where Idparts had their hot swap injectors done. They have the machine for calibrating Bosch pumps also
 

agent_jwa

Well-known member
Joined
Feb 9, 2024
Location
WI
TDI
02 Golf
That's where Idparts had their hot swap injectors done. They have the machine for calibrating Bosch pumps also
Yeah I actually talked to the sales guy at alliant power who does the sales to id parts. I gave him a part number off id parts and he was like that's our number. And we talked for a while and he looked up the exact parts I needed, this was at the Madison/deforest, WI location. I figured I'd have to wait for parts and he's like 'nope, we have everything in inventory'

From their website they have a lot of locations. Do they have a minimum order?
No they sold me exactly what I needed, they have like every single part in stock.
 

adriel1440

New member
Joined
Jan 1, 2025
Location
USA
TDI
1999 Volkswagen Jetta TDI ALH
Thanks for your support guys. I appreciate it lots.

I bought a used pump. Works well. The engine got up to 4k rpm easy. I didnt want to push it any further. I scanned the car with a Matco scanner my pops has. Still getting a start of injection control deviation code. And a new injection quantity adjuster upper limit code. Also engine coolant temperature circuit low? I decided to get VCDS and see more details.

My plans are to drain the fuel tank, fill up with new fuel, replace the filter, and use VCDS to find out whether this new pump’s timing works. I have been reading tutorials, watching videos and have a vague idea of what to check and what might fix the control deviation code.

So far, I am excited and pretty happy with how the car is running. Plenty of powa, but its still a work in progress.

My next question, what do i do with my old pump? Anyone taking cores? should i save it incase i need to rob parts? Rebuild it? So many options.

Thanks again for your support and a warm welcome to the community.
 

agent_jwa

Well-known member
Joined
Feb 9, 2024
Location
WI
TDI
02 Golf
Take it apart and see if the case is still useable and inspect every part closely. Then just order the parts you need and have a backup pump. They are pretty simple pumps compared to the old mechanical ve's.
 
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