Hey guys. One one of my TDIs the head started leaking at the big head o-ring. I got the Bosch seal kit and inside it came with a green o-ring. I have heard that you shouldnt stretch the green ones over the head because they arent as strong as the black ones. So do i go and buy a new black o-ring or can i stretch my green one on and over the head? I did the same thing on one of my previous TDIs but i had a black o-ring. Thanks in advance!
Injection pump head seal o ring
- Thread starter Minimim
- Start date
Prairieview
Veteran Member
- Joined
- Jul 9, 2017
- Location
- Too close to Sturgis 'ithole
- TDI
- Two 2000 Beetles, 2002 Jetta, 2002 gas avh Jetta, fleet of older 1.6 turbo and non's
Wish someone had told me this like 15 years ago....and to think I have been making a mistake all these trouble-free miles! Wow.
jimbote
Certified Volkswagen Nut
Many have done this without any real world penalty.
I followed this series of YouTube videos. It was bang on and all went smooth and by the numbers. My one issue was getting one of the bolts out of the IP. Got it out and replaced.
youtube.com
TDI Fuel Injection Pump Re-Seal
Go here and read the entire thread after watching all 7 TDI-pump-seal videos: http://forums.tdiclub.com/showthread.php?t=287336 Tools: * Razor knife (to scri...
Nuje
Top Post Dawg
- Joined
- Feb 11, 2005
- Location
- Island near Vancouver
- TDI
- 2002 Golf 6MT; 2015 Sportwagen 6MT; 2016 A3 e-tron 6DSG
I should have mentioned too I got my seals from DieselGeek. They sent the two special bits to get the one bolt and the middle o-ring in the head. Since I'm in Canada, didn't have to return them, so they sit in my tool box for the next time I might need them.
Starion_slider
Well-known member
I put a green one in mine like 10yrs ago. Stretched it on no problem. Make sure you really clean the groove out good with a pick. Thats not a job you want to have re-do multiple times if you can avoid it.
fatmobile
Veteran Member
For the old 1.6s, the kit always used a green o-ring for that.
No problem with streeeeeetch or breakage.
And everything is the same size as the TDI bosch rotary.
Putting a big cup over the head helps slide the o-ring up and keep it clean:
injectionpumpheadoring by vwfatmobile, on Flickr
To me the big concern is getting the slot clean. I use a pipe cleaner wrapped around where the seal rides.
Vasoline work well for lube.
Oh yeah the other big concern is that the pump needs to be turned until the plunger is all the way compressed,
so the tension won't release when you loosen the bolts, and let the spacer shim fall.
On the old pumps you could put a long bolt in the center hole and hold/push the plunger in to help.
Works on some of the cummins too.
I think the hole behind that 12mm center bolt on the TDI is really skinny. I could be wrong though.
It might have to be some kind a weird threaded pin.
No problem with streeeeeetch or breakage.
And everything is the same size as the TDI bosch rotary.
Putting a big cup over the head helps slide the o-ring up and keep it clean:
injectionpumpheadoring by vwfatmobile, on FlickrTo me the big concern is getting the slot clean. I use a pipe cleaner wrapped around where the seal rides.
Vasoline work well for lube.
Oh yeah the other big concern is that the pump needs to be turned until the plunger is all the way compressed,
so the tension won't release when you loosen the bolts, and let the spacer shim fall.
On the old pumps you could put a long bolt in the center hole and hold/push the plunger in to help.
Works on some of the cummins too.
I think the hole behind that 12mm center bolt on the TDI is really skinny. I could be wrong though.
It might have to be some kind a weird threaded pin.
STDOUBT
Veteran Member
The nice thing about the FKM (Viton) o-ring from DieselGeek is that it won't expand and shrink, expand and shrink if you alternate between BioDiesel and D#2. The shrinkage after running Bio then switching to #2 can actually result in leaking. Voice of experience.
JordanTr
Veteran Member
I recently installed a green one (all I had) and it stretched on there no issues.
No need for the special longer bolts either, I just used the longer pair that are normally on the pump head.
Good call on the cup! I plastered mine with duct tape to take care of any sharp edges for the o ring install.
No need for the special longer bolts either, I just used the longer pair that are normally on the pump head.
Good call on the cup! I plastered mine with duct tape to take care of any sharp edges for the o ring install.
If you follow the video series I posted, their instructions are east to follow and you don't need longer bolts or anything. Just wrapping that head in duct tape should be enough to keep things clean for the ring install.
I had no issues after doing mine last year.
I had no issues after doing mine last year.