Injector pump leaking

[Car959]

Hello all,
I have a 2000 golf manual tdi with the 1.9 engine. The injection pump has a small leak between the black apparatus on the drivers side of the pump (where all the fuel lines go into, I don’t know what it is called) and the pump itself.

It still runs like a scalded cat, but is a little hard to start after sitting for several days.

I have done quite a bit of research, however, my question is;

Do I need to replace the entire pump? Or is this a reseal job? Does anyone know a good mechanic in Arizona that can do the work? The car has 242k and I think the pump is original.

I got a quote from a shop for a sizzling $4500 to replace the pump.

Any advice is appreciated!
C959

 

[STDOUBT]

More like $50 max, if you're at all handy with little machines.

Injection Pump Seal Kits for VW TDI

You can reseal your own leaking VW TDI injection pump! If your 1996-2003 TDI injection pump is leaking diesel fuel, you have come to the right place! It's easy!

dieselgeek.com

That's not to say it isn't a foolproof procedure.
From your description, sounds like the head o-ring.
It's a bit tricky, and you have to be careful, but it's not brain surgery.
There are a few excellent walk-through's on here.
If you have access to any stiff biodiesel B50 or greater, there's a chance that o-ring will swell up and stop the leak.
The o-ring provided by DG is fluroelastomer, AKA Viton. Impervious to fuel oils, should last even longer than the original.
I recommend reading as many tutorials you can find until you feel confident to proceed.
Start, but don't end, here:

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

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...

forums.tdiclub.com

 

[STDOUBT]

Also check the "
Trusted TDI Mechanics - By State
thread at the top of the 101 forum.
ALMOST forgot to mention. There's a little wire coming off the N108 right under the leak you described!
Diesel will eat through that insulator if it sits on it too long (= $400 part replacement IF you can find one).
Clean it pronto, keep it clean.
BAD idea to run that car with a fuel leak!

 

[Car959]

Thank you very much!

 

[Car959]

After much research, I have decided to put a reman pump on my 2000 golf tdi manual transmission.

Does anyone have recommendations for where to get one?

 

[csstevej]

You can checked the for classified section section here for any one parting a Mk iv out….you can use either a 10 mm pump like you have or go with a 11 mm pump from an automatic…..it will also give you a boost in power with the manual injectors.
But it will cost you anywhere between 300-600 for a pump , plus either you need to install it yourself or pay a shop to install it and do it right….that will be another 500-800 depending on the shop.

Personally I’d do as STdoubt suggest……it will by far be the cheapest way to go.
Or find a guru in your area to help you.

 

[KLXD]

If you're going with a reman, look at the Vendors on this Site. NOT on ebay without serious research about the seller. Some there sell less than good quality.

 

[Abacus]

Where are you in Arizona?

 

[Car959]

Camp Verde, about 40 miles south of Sedona and 90 Miles north of Phoenix.

 

[Abacus]

I know right where it is, I'm next door to you in Dewey, just over the mountain. I've done pump reseals before but not for a few years. I primarily worked on B4's and A3's but have done some work on A4's. I don't consider myself a Guru but can muddle my way through.

 

[Car959]

You are too kind! I am thinking of putting in a reman. I want to drive to Oregon this summer and would rather not worry about the pump.
Any thoughts on where to get one that is reliable?

 

[csstevej]

You can try DFIS out of Portland Oregon. They rebuild them and have an excellent reputation.
But I would give Abacus a try , he’s been a member on here a long time and is well respected and it will be a hell of a lot cheaper too. If the leak is the only issue I’d reseal it ……if there’s something else that’s going on well then get a Re manufactured one….stay away from EBay as previously stated…..
I’ve resealed 3 different pumps in my stable , the highest milage on that is 427,xxx miles on it and still going strong.

 

[Abacus]

You can always get a good used pump and toss all new seals in it. It’s a lot easier out of the car.

 

[Car959]

That’s a great idea! I watched the video on replacing the seals, I am sure out of the car is much easier.

 

[KLXD]

If you're going to replace seals you might as well do it to your pump rather than an unknown used one. Though many have done it in the car I wouldn't. You have no idea how much dirt and corrosion you push the new seal over that you couldn't remove when backing the pump head out.

 

[Car959]

Thank you everyone for your excellent advice. I found a shop in Prescott that actually sounded as if they knew what they are taking about. They agreed to take out the old pump and put in a new one and the cost is not outragous. I am taking CSSTEVEJ’s advice and getting a rebuilt pump from DFIS in Oregon. I called on friday and they have one. More than I want to spend, but my ultimate goal is to drive the car from Arizona to Oregon this fall to see my sister. I think it might be money well spent.

 

[Car959]

Update; I am searching for a pump. DFiS does not have any pumps but I found one at The Diesel Store in Bolingbrook Ill. Does anyone have experience with The Diesel Store?

And, can I put a fuel injection pump out of an automatic into mine with a manual transmission? I read the automatics have a 11mm drive and the manuals 10mm. I don’t what to change injectors or get more power, but just wanted to know if it would work without making any other adjustments.

 

[csstevej]

Actually you’ll get a boost in power BECAUSE you have nozzles for a manual with a 11MM injector pump.
You may have to adjust the IQ which is easy , just need access to VCDS to set it.

 

[Prairieview]

Some people are just hell-bent on spending money. Forget logic. Forget personal satisfaction from learning how to do stuff on their own. SPEND THAT MONEY!!!!!!!! Put the spurs to that credit card. Show it who the boss is!!!!

 

[Car959]

Wow! Mmm. A lot of assumptions in that reply. But thank you.

 

[javik1]

Some people are just hell-bent on spending money. Forget logic. Forget personal satisfaction from learning how to do stuff on their own. SPEND THAT MONEY!!!!!!!! Put the spurs to that credit card. Show it who the boss is!!!!

My son always asks me "why did you learn to do this or that whether it is mechanic, carpentry, etc...." my response is "out of necessity" if you do not have enough money to pay..then you DIY

 

[Abacus]

I agree. There was a time when I had to DIY, and I am thankful I did learn, although not at the time. Today I can afford to have someone else do the work but choose not to because they don’t use the same attention to detail I do. There is nothing wrong with paying someone else to do something.

 

[Car959]

Thank you.

 

[STDOUBT]

Car959,
When you get that pump swapped, try and have the shop give you the old pump.
Worth a couple hundred easy even with a leak!
What's the mileage on your '00?

 

[pkhoury]

Car959,
When you get that pump swapped, try and have the shop give you the old pump.
Worth a couple hundred easy even with a leak!
What's the mileage on your '00?

Yup. 10mm pumps go on ebay close to $200 and 11mm for $300.

If you have the tools and are mechanically inclined, it's fairly easy to do it yourself. I know at a junkyard, I can pull the pump, injectors, fuel lines and injector hold downs in about 30 minutes. Putting all that stuff back on, maybe 90 minutes after setting the pump voltage where I want it to be in VCDS/hammer modding.

 

[Car959]

Thanks you guys! Yes, I kept the old pump and plan to reseal it after I get more education!

 

[Car959]

The milage on my golf is 242K

 

[AndyBees]

Wow, 242k miles on the IP is hardly past break-in. And, it is not unusual for one to develop a leak at those miles and age. In the last year, I've resealed several IPs having miles from 250k to over 300k. It is a fairly easy task. Runonbeer has a good How To on the topic. There's a lot of YouTube vids on it too.

 

[markdave]

Hello all,
I have a 2000 golf manual tdi with the 1.9 engine. The injection pump has a small leak between the black apparatus on the drivers side of the pump (where all the fuel lines go into, I don’t know what it is called) and the pump itself.

It still runs like a scalded cat, but is a little hard to start after sitting for several days.

Speed Test​

I have done quite a bit of research, however, my question is;

Do I need to replace the entire pump? Or is this a reseal job? Does anyone know a good mechanic in Arizona that can do the work? The car has 242k and I think the pump is original.

I got a quote from a shop for a sizzling $4500 to replace the pump.

Any advice is appreciated!
C959

you can use either a 10 mm pump like you have or go with a 11 mm pump from an automatic…..it will also give you a boost in power with the manual injectors.