I never thought that I would be back on this thread, but my newly acquired (second) green B4 started dripping diesel at the head pump seal. I tackled this job in 2012 for my daily driver B4 in a previous post here. I prepped myself by reviewing the seven YouTube videos that Robby Plenge and Jim Royston thankfully put together.
I got in the garage about 6 AM and had my tools put away about 2 PM, but I did take pictures, notes and had a meal. I also used VCDS for setting the Injection Quantity:
and used the timing graph to advance the timing as it was very retarded before starting the reseal:
I did not use the seal provided in the Bosch Seal Kit, but again tried to use the Vaseline coated AS568-229 3.53 mm fat O-ring, but it just refused to seat in the pump body. I wound up using the smaller AS568-142, which is only 2.36 mm thick.
Here is pump head out with the broken, pick pried leaking O-ring:
I also wanted to show you a sketch showing the front of injection pump head and the various bolts and brackets:
Here it is in PDF if you want a copy:
I did have one challenge that I could not overcome, and really don't know what to do about. The bolt (my arbitrary #14 in the sketch) that goes through the bottom bracket on the pump head and connects though to the engine attached bracket could not be reattached. The cone tapered nut is supposed to mate into the engine bracket but I couldn't get this happen. Here is the nut/bolt:
I tried everything I could think of to get that nut to stay put while starting the bolt but I could not get the nut to stay put. So I have the two front bolts and the one top rear bracket bolt holding my diesel injection pump in position. What do you think? With regards to Meatloaf, is 3 out of 4 not bad??? Jeff