Mike did you find the seal or gasket for the side module and socket? I have the same question and can't seem to find the answer? ThanksOK, here we go. I am new to TDIclub. I am owner of a couple ov VWs, as well as service manager of a diesel fuel shop in GA.
I have a customer's '96 Jetta with the fuel leak at F.I.P.
I replaced the top cover oring...still leaks at sensor/module(?) bolted to the side of the pump. This module has a cable running out of the right side and has had silicone run all the way around it in a futile attempt to stop the leak.
I cannot seem to locate the special socket for the tamper proof screw on the module. I do have the top cover socket, but it is larger than the one needed for the module.
We don't work on this model pump in our shop so I have very limited info. What type of seal or gasket is behind the module? And is this seal or gasket in the Bosch pump overhaul kit? Thanks, Mike
Hello: He and I are looking for a different socket and seal,
it is bolted to the side of the IQ positioner with the wires coming out of it.
Link is not good. Any thoughts appreciated.
This appears to imply your leak is not a "user-serviceable" problem.Dieselgeek said:This kit contains all possible user-serviceable seals for the TDI injection pump.
I started using this this summer and now mine is leaking. I'm not sure it's because of the additive or just wear.Also don't use lucas fuel injector cleaner it says on the bottle for diesel but I started using it and my injector started leaking. Just giving you guys a heads up.
I wish I had seen this thread sooner - I just went through the equally frustrating experience. I ordered both thicknesses in Viton from the web site you mentioned. Many thanks for your research!First of all, I have to say THANK YOU to both club members and vendors runonbeer (Robby Plenge, www.runonbeer.com) and dieselgeek (Jim Royston, www.dieselgeek.com) for producing and making available on YouTube the seven videos on how to replace the 3 prone to leak seals on the Bosch diesel injection pump. I probably wouldn’t have attempted this seal replacement without these instructional videos.
With 262,000 miles on my 1997 Passat, my TDI developed a head pump seal leak, splattering destruction on two 3 way hoses and one water pump to radiator hose. Repeating their demonstration, I replaced both my quantity adjuster bottom seal and head pump seal with the seals provided in the Bosch Seal Kit P/N: 2 467 010 003-002. I’m thinking: Problem Solved.
Much to my surprise after a couple of weeks of routine driving, that familiar diesel smell returns along with, you guessed it, a head pump seal leak! I was careful when removing the original seal with a pick to not score or scratch the head seal groove; therefore, I was certain that I did not create a seal failure scenario. Now I am thinking that maybe, just maybe, I should have installed the runonbeer/dieselgeek recommended more impervious to failure Viton seal instead of the Bosch (green) seal. So I ordered a pair of the Viton head seals from dieselgeek and repeated the whole process a SECOND TIME. I’m thinking: I sure hope this works.
About two weeks of driving later…. don’t say it!!! Yes, it’s sad, but true: drip, drip, drip. OK, now I’m frustrated, but I will solve this problem. I grab my budget metal rule and cheapo, but accurate Brookstone plastic caliper. I had replaced the injection pump top cover a couple of years ago, when it started leaking and had bought the Bosch Seal kit then, so I had both an original Bosch O ring and the second Viton O ring seal to compare measurements. Both O rings measured almost exactly the same actual inside diameter (I.D.) of 60.0 mm. The green Bosch O ring thickness (actual cross section) looked like 2.5 mm thick. The Viton seal was skinnier; it looked like 2.3 mm thick. Unfortunately, I didn’t have access to a micrometer.
I surfed to www.marcorubber.com and found that O-Rings have a Standard AS568 for sizing. Using their Sizing Chart, I concluded that the AS568-142 is the correct/actual size O ring (59.99 mm I.D. with 2.36 mm thickness). I searched the sizing charts and found that the next thicker (fatter) O ring was the AS568-229: still 59.92 mm I.D. but now with a 3.53 mm thickness. I bought both the Buna and Viton types and installed the Buna. I coated this O ring with Vaseline and slowly and evenly tightened the four head pump screws to return the pump head into the pump body without stripping threads.
So far, so good: no leaks. I did have to insert a new M6 x 45mm bolt with Permatex threadlocker Blue on it to replace the lower front pump head bolt that vibrated out. Also, I did have to replace the two copper washers on both sides of the top cover banjo fuel line fitting that were worn out and dripping diesel. One final note, after you have blindly aligned the quantity adjuster (peg into hole) onto the pump body, do not then attach your steel fuel injector lines. After you’ve primed the pump with the MityVac, throw a rag in front of the pump head and then crank the starter. If you did not correctly align the peg into the hole, you won’t get any diesel shooting out onto your rag. Ask me how I know. Then connect up your lines and continue with VAG-COM injector Quantity adjustment.
One more time, Thank You, Thank You: Robby and Jim.
Hey, there is tons of info here, just take your time and search and research.Help I have the same leaky black box on the pump. Info please. No more Lucas for me either. Some one put a pic up on previous page.
I hope you are wrong. Here is a pic of the module. Can it be sealed and is a socket available. It is different than the top socket. I know Bosch must have them. Thanks.
This This "box" cannot be removed from the QA housing. It is basically an adapter housing that seals the wires into the Q/A housing. The wire leads on the inside of the pump are solid wires that are welded (not soldered) to the stand-off assembly. It is very rare to develop a leak here because there are actually two seals behind the "black box", but if you do, you are out of luck and will need another pump (the seals are not available from Bosch because the Q/A assembly is considered by Bosch to be non-serviceable because the special process used to weld the wires inside cannot be duplicated in the field.