How to video: On car VE injection pump seal replacement video

runonbeer

Maintenance EnthusiastVendor
Joined
Apr 15, 2002
Location
Austin, TX/Chapel Hill, NC
TDI
'00 Golf 02M, '10 Golf 02E, '02 UTE 02M
This is the one that we have been waiting for. It shows, in detail, how to replace the three most-likely-to-be-leaking seals on an ALH injection pump: the top cover, quantity adjuster & head seal. It is also applicable to the pumps on the A3/B4 cars.

It is long, but some will appreciate this. There are seven parts. Watch all 7 before beginning the repair to ensure you have all tools and equippment on hand. VCDS required!

Grab your T-30 and watch this:

https://m.youtube.com/playlist?list=PLUNS-IqlfxwCxLPoYGeI_-E_O_dsBkDp1
 
Last edited:

chlavenka

Member
Joined
Jul 22, 2006
Location
San Francisco
TDI
2002 Golf
I see many posts about the three main injection pump seal replacements (head, top, and middle). My question is about the other side, or timing belt/sprocket side. Is there a replaceable seal here where it mounts onto the bracket, and if so, is it included in one of the seal kits for sale?
I've looked with a light and mirror all around and my pump really seems to have a small, slow leak emanating from all around this mount.
-2002 Golf TDI, ALH
-Carl
 

mtbr297

Vendor
Joined
Nov 3, 2002
Location
Ft. Worth, TX., USA
TDI
2015 Golf TDI, Seat Leon FR PD 150 6 speed.
I see many posts about the three main injection pump seal replacements (head, top, and middle). My question is about the other side, or timing belt/sprocket side. Is there a replaceable seal here where it mounts onto the bracket, and if so, is it included in one of the seal kits for sale?
I've looked with a light and mirror all around and my pump really seems to have a small, slow leak emanating from all around this mount.
-2002 Golf TDI, ALH
-Carl
The front seal isn't a job you can do without taking it to a pump shop. I requires removing the hub and the hub isn't keyed and nearly impossible to put back in the correct position. So if the front seal is leaking you will need a complete pump rebuild by dfis in Portland.
 

KCEE

Member
Joined
May 17, 2009
Location
FT Worth
TDI
2001 NB
Excellent how to! I just changed my seals, it took me several attempts. Let me explain what I found out, it may help someone else. I bought two kits $12.95 ea just in case I messed up. I also went to a local O ring shop and bought three Viton seals. The first seal I scuffed so I did the job again. Broke the second seal somehow. The third seal I really took my time and used the utmost care. after assembly I still could not get the pump to prime (using the method in the video) so I took out the seal thinking I must have damaged it. It was perfect so I reinstalled it and changed the cover and adjuster plate gaskets again. Still would not prime. Thought the vitons must be the wrong size so I replaced with the Bosch O ring. Still would not prime. Then I thought that I would remove the adjuster plate and fill the pump with diesel. It worked! The pump took the prime, bled the injectors, set IQ and now I am very happy. One point I wish to reiterate, do not take all of the fuel out of the pump. If you do it may be extremely hard to prime.
 

runonbeer

Maintenance EnthusiastVendor
Joined
Apr 15, 2002
Location
Austin, TX/Chapel Hill, NC
TDI
'00 Golf 02M, '10 Golf 02E, '02 UTE 02M
When you back the pump head out of the body to replace the seal, you will "remove all of the fuel from the pump." It's unavoidable. I'm not quite sure what problem you were encountering there.

Congratulations and thanks for the bump!
 

Jerry_T

Veteran Member
Joined
Jun 7, 2005
Location
Charlotte, N.C.
TDI
2001 Golf Silver, 2006 Jetta White & Red, 2014 Passat
Very nice vid ! ! ! Great attention to detail.

Is it possible and / or advisable to replace the quantity adjuster?

Mine has the flashing glow plug light and has thrown a code indicating QA out of range. I have messed with the adjustment but no change. She surges at idle and the fuel economy has dropped.

If replaceable, where might I purchase one?

Thanks,

JT
 

sqhschief

Veteran Member
Joined
Sep 28, 2008
Location
Tennessee
TDI
2000 Jetta TDi, 1981 Chevrolet LUV Diesel! Non-turbo :(
Very nice vid ! ! ! Great attention to detail.

Is it possible and / or advisable to replace the quantity adjuster?

Mine has the flashing glow plug light and has thrown a code indicating QA out of range. I have messed with the adjustment but no change. She surges at idle and the fuel economy has dropped.

If replaceable, where might I purchase one?

Thanks,

JT
You have a lot of cars :eek:
 

Vesparide

Active member
Joined
Oct 30, 2008
Location
PoCo, B.C.
TDI
1999.5 Golf TDI
GREAT VIDEO!!
I just did my seal with the video and it was very detailed oriented. Follow it to a "T" and you won't go wrong. Runonbeer advises on another post to replace the head plug seal, excellent idea, but you will have to fabricate a specific tool to remove the head plug which is in the middle of the head between the injector outlets.
Mine was leaking there also. 15/16" 6 point socket with 3 sides rounded out.:D
 

Losha

Veteran Member
Joined
Mar 8, 2005
Location
Sioux Falls, SD
TDI
06 Jetta TDI DSG, 2001 Golf TDI, 97 Passat TDI, 02 NB 1.8T, 01 A4 1.8T
The front seal isn't a job you can do without taking it to a pump shop. I requires removing the hub and the hub isn't keyed and nearly impossible to put back in the correct position. So if the front seal is leaking you will need a complete pump rebuild by dfis in Portland.
Actually you can replace front seal easily if you know how & pump is still in good condition, doesnt have too much wear on housing from rollers.;) I have done lot of them for past 2 years with great success, the first one did on customers car and he been driving for 2 years now no issues.:)
 

runonbeer

Maintenance EnthusiastVendor
Joined
Apr 15, 2002
Location
Austin, TX/Chapel Hill, NC
TDI
'00 Golf 02M, '10 Golf 02E, '02 UTE 02M
Way better off doing it in the car. The timing belt will hold the pump in the on cam position.

Perhaps you should actually watch the video.
 

Losha

Veteran Member
Joined
Mar 8, 2005
Location
Sioux Falls, SD
TDI
06 Jetta TDI DSG, 2001 Golf TDI, 97 Passat TDI, 02 NB 1.8T, 01 A4 1.8T
Its better to do in the car if your are only replacing head and top seals, but if want to replace front seal or timing piston cover seals and bottom sensor (cant remember what its called right now), then you have to remove pump to do on bench.
 

B100

Veteran Member
Joined
Jan 7, 2003
Location
Berkeley, Eastbania
TDI
2003 Golf
I wish this video could have been done on a bench. I would not do this while on the car.
I easily replaced the large O-ring on the driver's side while the pump was in the car, and this video was a large help with that. In addition to the fantastic writeup by DieselGeek.
 

CopaMundial

Veteran Member
Joined
Jan 30, 2011
Location
Southeastern PA
TDI
03 Jetta Wagon 5sp (New to me Oct 2014) 03 Jetta 5sp (RIP Aug 2014)
It's sad to think about how many people go through their entire lives and never find an online resource as helpful as Fred's. To those poor lost souls the internet is nothing but porn, pop-up ads, and Aunt Rita's inane facebook messages.

This thread has motivated me to make another donation to TDIClub as a sign of my ever-increasing appreciation for community members who are so generous with their time and knowledge.
 

tommydee

Active member
Joined
Aug 1, 2003
Location
Round Rock, Texas
TDI
Jetta Wagon-GLS, 2003, Silver
I just did this job - one note !! DO NOT forget to tighten the nut for the fuel shutoff wire !! Dont ask how I found this out !!! I got in a hurry to finish and failed to tighten it fully - had it start fine and just die for no reason - until an hour later i figured out my mistake.

One other note - YOU REALLY need the mirror to make sure the o ring is seated on the bottom ...

Just my 2cents
 

whitedog

Veteran Member
Joined
Jul 12, 2004
Location
Bend, Oregon
TDI
2004 Jetta that I fill by myself
After playing with a junk pump on the bench and watching the video, I'm comfortable doing this if I ever need to. I used to be scared of it, but now, I'm confident I can do it right the first time. Thanks, Robby.
 

ELM

Veteran Member
Joined
May 25, 2011
Location
Sutter Creek CA
TDI
2002 Beetle 5 speed swap
I just did the IP seals on my 2002 beetle yesterday and it went great no more leaks and the video helped so much to watch it being done. Today I just finished the timing belt kit from Dieselgeek.
 

whitedog

Veteran Member
Joined
Jul 12, 2004
Location
Bend, Oregon
TDI
2004 Jetta that I fill by myself
Funny thing when I was looking at the videos. I noticed there were about 3-5000 views then there was another video listed about Cancun and it had over 2,000,000 views. I wonder if it had anything to do with the girls in the bikinis?
 

jdross440

Well-known member
Joined
Mar 1, 2009
Location
Arkansas
TDI
2002 Jetta
I did mine Friday. Without the video I would have pulled the pump and taken to a rebuild shop. Saved me a bunch of money. Thanks for the excellent job. As a side note the fuel leaking down on the alternator took it out, so had to replace it also. Replace 90A with a 120A.
 
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