Diesel pump leaking 1.9tdi -help new problem ;(

User avatar
SpikePCR
Cadet
Posts: 641
Joined: Tue Aug 21, 2007 1:36 pm
Membership No: missing
Location: JHB
Contact:

Diesel pump leaking 1.9tdi -help new problem ;(

Postby SpikePCR » Fri Jul 08, 2016 8:29 pm

I have a golf 4 tdi ahf engine. My diesel pump is leaking fuel. Can I replace the seals or do I need a new pump?
Last edited by SpikePCR on Sun Jul 17, 2016 6:15 pm, edited 1 time in total.

User avatar
panic-mechanic
Panic's Place
Posts: 24047
Joined: Mon Jul 29, 2002 9:08 am
Membership No: 79
Location: Benoni, putfontein.
Contact:

Re: Diesel pump leaking 1.9tdi

Postby panic-mechanic » Sat Jul 09, 2016 6:23 pm

Northern Diesel in pretoria. Phone them. make an appointment. Drop car. Cry when you pay the bill.
But that is about the only people I would let touch it if it was mine.
Just check that it is not a loose bolt or nut on a pipe.
http://www.northerndiesel.co.za/DIESEL%20PUMPS.htm
Stephan van Tonder - Jhb - Putfontein Benoni
'07 Audi S6 V10 - beast !!!!!
'05 Audi A6 3.0L TDI Avant
'07 Audi A4 2l TDI
'95 Audi 90 coupe quattro
'13 VW CC 2l tdi (repair project)
'05 Touareg v10

Perfect Power dealer. I do dyno tuning.

User avatar
SpikePCR
Cadet
Posts: 641
Joined: Tue Aug 21, 2007 1:36 pm
Membership No: missing
Location: JHB
Contact:

Re: Diesel pump leaking 1.9tdi

Postby SpikePCR » Sat Jul 09, 2016 8:30 pm

panic-mechanic wrote:Northern Diesel in pretoria. Phone them. make an appointment. Drop car. Cry when you pay the bill.
But that is about the only people I would let touch it if it was mine.
Just check that it is not a loose bolt or nut on a pipe.
http://www.northerndiesel.co.za/DIESEL%20PUMPS.htm



Thanks Panic I called them the guy that strips the car is on leave for 2 weeks. They can only assist me for now if I can strip the pump and send it to them. Cost will be -+ R8k. Is it a hard job to strip?

User avatar
Tdi jetta 4 ever
Lieutenant-Colonel
Posts: 4062
Joined: Sat Oct 23, 2010 9:47 am
Car Make: VW
Car Model: Jetta 4 1.9 Tdi, Isuzu2.5DKBLe
Membership No: missing
Location: Fochville
Contact:

Re: Diesel pump leaking 1.9tdi

Postby Tdi jetta 4 ever » Sat Jul 09, 2016 9:26 pm

There is no way that it will cost that much to fix a leak. :fear:
It can be as simple as a gasket or o-ring that needs to be replaced. Which wil not even cost you more than a R100
Just get someone who will be able to fit it for you.
Robin
Current rides: 02' Jetta 4 1.9 Tdi, 99' Isuzu KB 250 Dle(Faithfull aka slowmo) Audi A4 B7 2.0 Tdi Multitronic(non runner)
Ex rides: 82' jetta 1.5 Gls(sold), 88' jetta Clx(sold with tears in my eyes)

Rather buy a good quality part that will last then buying a cheap part that won't last.


VCDS user with HEX-USB+CAN cable(Rosstech)

[email protected]

User avatar
amstel18
Lieutenant-Colonel
Posts: 4456
Joined: Mon Dec 24, 2007 9:54 am
Car Make: VW
Car Model: Polo TSI
Membership No: missing
Location: Brackenfell, Cape Town
Contact:

Re: Diesel pump leaking 1.9tdi

Postby amstel18 » Sat Jul 09, 2016 10:32 pm

I recall martin doing the seals on his jetta a while back.

Theres plenty diy's on the old ve motors so cant be too difficult to do. Certainly not 8k difficult

Sent from my D5503 using Tapatalk
Current:
2013 Audi A3 Sportback 1.8 TFSI S-Tronic
Ex:
2015 Pure White 1.2tsi Comfortline
2011 2L BiTdi ROK D/C Highline
2006 Seat Ibiza Cupra TDI
91 Caddy, ADY motor on mp9, wildcat 4-1 branch and 50mm Evolution s/s exhaust
96 1600 Chico (sold)

User avatar
SpikePCR
Cadet
Posts: 641
Joined: Tue Aug 21, 2007 1:36 pm
Membership No: missing
Location: JHB
Contact:

Re: Diesel pump leaking 1.9tdi

Postby SpikePCR » Sun Jul 10, 2016 7:05 am

8k was to replace all the seals and recalibrate

SilverFox
Cadet
Posts: 52
Joined: Mon Jan 16, 2012 7:51 pm
Car Make: VW
Car Model: Golf MK3 GSX, Golf IV TDi
Membership No: missing
Location: Cape Town
Contact:

Re: Diesel pump leaking 1.9tdi

Postby SilverFox » Sun Jul 10, 2016 9:19 am

Seal kit is a few hundred bucks from Bosch. Series of diy videos on youtube. First one here: https://youtube.com/watch?v=VR44StvcXms
See http://www.myturbodiesel.com/wiki/fuel- ... placement/ as well.
I bought the kit, but then the pump somehow stopped leaking.
There is a tamper proof bolt that has a triangular shape head. Can be removed by hitting a hex socket over it.
Calibration done via vcds. Not a R8000 job imo.
Image

LoW n SloW
Lieutenant
Posts: 1913
Joined: Fri Nov 04, 2011 10:12 pm
Location: dbn
Contact:

Re: Diesel pump leaking 1.9tdi

Postby LoW n SloW » Sun Jul 10, 2016 10:33 pm

Ey some people in the automotive business take other people for a ride
2001 'rolla 160 gle (ex)
2000 'rolla facelift RSi (ex. miss this) - exhaust and vernier
2005 old schooled caddy (ex)
2001 'rolla RXi airbag spec (ex) - exhaust, vernier, cai
1995 vw golf 1 ((ex)
2006 seat ibiza FR 1.9 TDI (current) - cupra FMIC, straight pipe, RK mild nandos chicken sauce 132wkw, 426nm
2012 Audi A1 1.6 TDI (stock as they come)

User avatar
amstel18
Lieutenant-Colonel
Posts: 4456
Joined: Mon Dec 24, 2007 9:54 am
Car Make: VW
Car Model: Polo TSI
Membership No: missing
Location: Brackenfell, Cape Town
Contact:

Re: Diesel pump leaking 1.9tdi

Postby amstel18 » Mon Jul 11, 2016 6:57 am

Here's the link to martin's rides thread:

http://vwclub.co.za/forum/viewtopic.php ... p#p1983915
Current:
2013 Audi A3 Sportback 1.8 TFSI S-Tronic
Ex:
2015 Pure White 1.2tsi Comfortline
2011 2L BiTdi ROK D/C Highline
2006 Seat Ibiza Cupra TDI
91 Caddy, ADY motor on mp9, wildcat 4-1 branch and 50mm Evolution s/s exhaust
96 1600 Chico (sold)

User avatar
SpikePCR
Cadet
Posts: 641
Joined: Tue Aug 21, 2007 1:36 pm
Membership No: missing
Location: JHB
Contact:

Re: Diesel pump leaking 1.9tdi

Postby SpikePCR » Mon Jul 11, 2016 7:25 am

Thanks guys going to try the diy. Anyone has that anti tamper nut removal tool to lend me or know where I can buy it from

tdnaicker
Enlisted
Posts: 157
Joined: Tue Aug 19, 2008 8:59 am
Contact:

Re: Diesel pump leaking 1.9tdi

Postby tdnaicker » Mon Jul 11, 2016 11:04 am

I had the same issue.

Seals shrunk due to using 50 ppm diesel.

Switched to 500 ppm and the leak is gone now.

If you prefer changing the seals then this can be done with the pump on the car as per the video link in posted already .

User avatar
SpikePCR
Cadet
Posts: 641
Joined: Tue Aug 21, 2007 1:36 pm
Membership No: missing
Location: JHB
Contact:

Re: Diesel pump leaking 1.9tdi -help new problem ;(

Postby SpikePCR » Sun Jul 17, 2016 6:20 pm

So I decided to do the DIY as I was away on leave. I followed the videos accurately except I did not mark the cover position on the pump ;(. Now car only swings and no start. I bled the injectors and fuel is flowing thru all four. What else can I check before I tow the car to a diesel place or is there anyone in the east rand that can assist me please

User avatar
panic-mechanic
Panic's Place
Posts: 24047
Joined: Mon Jul 29, 2002 9:08 am
Membership No: 79
Location: Benoni, putfontein.
Contact:

Re: Diesel pump leaking 1.9tdi -help new problem ;(

Postby panic-mechanic » Sun Jul 17, 2016 6:34 pm

so did you make timing marks before stripping, set it all to tdc and set it exactly the same after?.
Have you installed the fuel pipes in the correct order?.

I am in the east rand but swamped with work. How much of a hurry?.
Stephan van Tonder - Jhb - Putfontein Benoni
'07 Audi S6 V10 - beast !!!!!
'05 Audi A6 3.0L TDI Avant
'07 Audi A4 2l TDI
'95 Audi 90 coupe quattro
'13 VW CC 2l tdi (repair project)
'05 Touareg v10

Perfect Power dealer. I do dyno tuning.

VAG Fan
Cadet
Posts: 400
Joined: Tue Mar 15, 2016 1:54 pm
Location: Pretoria
Contact:

Re: Diesel pump leaking 1.9tdi -help new problem ;(

Postby VAG Fan » Mon Jul 18, 2016 12:07 pm

Stephan,

Why would the cambelt timing be out, requiring marks and TDC, if only the VE pump seals have been replaced? As far as I've been able to see on various videos, the pump stays in the car, and nothing is done on the cambelt / valve-train. It's only the cover (one seal) and the metering unit (another seal) that are removed from the VE pump. The metering unit needs to be positioned correctly when re-assembling, in order to get correct fuelling.

I'm really beginning to wonder how this job can cost R6k or more.
1992 Audi 500 SE, type C4, AAR, 330k
1990 VW Fox, type 16, HM, 230k
2004 VW Golf, type 1J, AHF, 208k
- - - - - - - - - -
Experience with maintaining KE-III Jetronic injection and some carburetors
Getting familiar with 1st-generation TDI technology

User avatar
panic-mechanic
Panic's Place
Posts: 24047
Joined: Mon Jul 29, 2002 9:08 am
Membership No: 79
Location: Benoni, putfontein.
Contact:

Re: Diesel pump leaking 1.9tdi -help new problem ;(

Postby panic-mechanic » Mon Jul 18, 2016 12:31 pm

Yeah apparently he did not remove the pump.
I assumed he did as I would personally not like to do that with the pump in place.

http://forums.tdiclub.com/showthread.php?t=218789
Last edited by panic-mechanic on Mon Jul 18, 2016 12:42 pm, edited 1 time in total.
Stephan van Tonder - Jhb - Putfontein Benoni
'07 Audi S6 V10 - beast !!!!!
'05 Audi A6 3.0L TDI Avant
'07 Audi A4 2l TDI
'95 Audi 90 coupe quattro
'13 VW CC 2l tdi (repair project)
'05 Touareg v10

Perfect Power dealer. I do dyno tuning.

User avatar
SpikePCR
Cadet
Posts: 641
Joined: Tue Aug 21, 2007 1:36 pm
Membership No: missing
Location: JHB
Contact:

Re: Diesel pump leaking 1.9tdi -help new problem ;(

Postby SpikePCR » Mon Jul 18, 2016 12:36 pm

panic-mechanic wrote:Yeah apparently he did not remove the pump.
I assumed he did as I would personally not like to do that with the pump in place.


correct :). Car is being towed to Stephan tonite :). Thank you again Stephan for helping me in such short notice.

VAG Fan
Cadet
Posts: 400
Joined: Tue Mar 15, 2016 1:54 pm
Location: Pretoria
Contact:

Re: Diesel pump leaking 1.9tdi -help new problem ;(

Postby VAG Fan » Mon Jul 18, 2016 1:28 pm

Ah, OK, I understand.
1992 Audi 500 SE, type C4, AAR, 330k
1990 VW Fox, type 16, HM, 230k
2004 VW Golf, type 1J, AHF, 208k
- - - - - - - - - -
Experience with maintaining KE-III Jetronic injection and some carburetors
Getting familiar with 1st-generation TDI technology

User avatar
SpikePCR
Cadet
Posts: 641
Joined: Tue Aug 21, 2007 1:36 pm
Membership No: missing
Location: JHB
Contact:

Re: Diesel pump leaking 1.9tdi -help new problem ;(

Postby SpikePCR » Wed Jul 27, 2016 8:51 pm

Car was with panic mechanic and the diagnosis is bad. I have a broken shaft in the diesel pump. So I need a new injector pump. Does anyone have one for sale or know of anyone selling one please let me kniw

Rudi46
Cadet
Posts: 589
Joined: Mon Oct 12, 2009 4:07 pm
Car Make: Nike
Car Model: Walk and see more
Membership No: missing
Location: Meyerton
Contact:

Re: Diesel pump leaking 1.9tdi -help new problem ;(

Postby Rudi46 » Thu Jul 28, 2016 1:32 pm

SpikePCR wrote:Car was with panic mechanic and the diagnosis is bad. I have a broken shaft in the diesel pump. So I need a new injector pump. Does anyone have one for sale or know of anyone selling one please let me kniw


How did that happen? Wrong installation of the seals?
Current - VW Golf MK4 TDi Estate
Ex - 00 Triumph Sprint ST(Stollen)
Ex - 83 Caddy
Ex - 01 Golf 4 Tdi
Ex - 02 Audi S3
Ex - Kartcraft Kestrel beach Buggy
Ex - 98 Golf Chico 2L
Ex - 92 Citi shuttle 2L
Ex - 90 Yamaha FZR1000
Ex - 90 Honda CBR400
Ex - 03 Honda NSR150SP

VAG Fan
Cadet
Posts: 400
Joined: Tue Mar 15, 2016 1:54 pm
Location: Pretoria
Contact:

Re: Diesel pump leaking 1.9tdi -help new problem ;(

Postby VAG Fan » Thu Jul 28, 2016 1:46 pm

Ditto, was wondering the same thing.
1992 Audi 500 SE, type C4, AAR, 330k
1990 VW Fox, type 16, HM, 230k
2004 VW Golf, type 1J, AHF, 208k
- - - - - - - - - -
Experience with maintaining KE-III Jetronic injection and some carburetors
Getting familiar with 1st-generation TDI technology

User avatar
SpikePCR
Cadet
Posts: 641
Joined: Tue Aug 21, 2007 1:36 pm
Membership No: missing
Location: JHB
Contact:

Re: Diesel pump leaking 1.9tdi -help new problem ;(

Postby SpikePCR » Thu Jul 28, 2016 2:57 pm

Rudi46 wrote:
SpikePCR wrote:Car was with panic mechanic and the diagnosis is bad. I have a broken shaft in the diesel pump. So I need a new injector pump. Does anyone have one for sale or know of anyone selling one please let me kniw


How did that happen? Wrong installation of the seals?


Must be :(

User avatar
Tdi jetta 4 ever
Lieutenant-Colonel
Posts: 4062
Joined: Sat Oct 23, 2010 9:47 am
Car Make: VW
Car Model: Jetta 4 1.9 Tdi, Isuzu2.5DKBLe
Membership No: missing
Location: Fochville
Contact:

Re: Diesel pump leaking 1.9tdi -help new problem ;(

Postby Tdi jetta 4 ever » Thu Jul 28, 2016 7:16 pm

Damn this is bad news. Will see if i can find something
Robin
Current rides: 02' Jetta 4 1.9 Tdi, 99' Isuzu KB 250 Dle(Faithfull aka slowmo) Audi A4 B7 2.0 Tdi Multitronic(non runner)
Ex rides: 82' jetta 1.5 Gls(sold), 88' jetta Clx(sold with tears in my eyes)

Rather buy a good quality part that will last then buying a cheap part that won't last.


VCDS user with HEX-USB+CAN cable(Rosstech)

[email protected]

User avatar
Cass
Cadet
Posts: 263
Joined: Sat Jan 05, 2008 11:51 am
Car Make: vw
Car Model: Mk4 tdi
Membership No: missing
Location: Pretoria. East
Contact:

Re: Diesel pump leaking 1.9tdi -help new problem ;(

Postby Cass » Mon Aug 01, 2016 12:53 pm

Just do a quick search around junkmail ir gumtree. Those rotory style ve pumps dont acrually fail on a regular basis. Just prime the pump with 500ppm and some turbo injector cleaner/ lubricator. This will reseal those old seals...
current: vw Golf mk4
1.9 Tdi

Ex: 92 citi rocketship (stolen)

User avatar
SpikePCR
Cadet
Posts: 641
Joined: Tue Aug 21, 2007 1:36 pm
Membership No: missing
Location: JHB
Contact:

Re: Diesel pump leaking 1.9tdi -help new problem ;(

Postby SpikePCR » Mon Aug 01, 2016 12:58 pm

Cass wrote:Just do a quick search around junkmail ir gumtree. Those rotory style ve pumps dont acrually fail on a regular basis. Just prime the pump with 500ppm and some turbo injector cleaner/ lubricator. This will reseal those old seals...



Thanks bud Panic Mechanic(Stephan) has been down with bronchitis and as soon as time permits he will get to the car. Will keep you guys posted.

User avatar
panic-mechanic
Panic's Place
Posts: 24047
Joined: Mon Jul 29, 2002 9:08 am
Membership No: 79
Location: Benoni, putfontein.
Contact:

Re: Diesel pump leaking 1.9tdi -help new problem ;(

Postby panic-mechanic » Mon Aug 01, 2016 1:28 pm

Yeah sorry about the delay.
Only sort of back on my feet today again. Have been pretty much man down since wed last week.
Ideally when You do the rear section the pump must be sitting vertically in a workbench and the VW service manual for seal replacement also states this. Yet guys find removing the pump too much work and attempt it in the car. Personally I would never do that.
The issue is this. When You do the rear section here is what goes wrong. and if you refer to that link I posted earlier the guys describes it very well and how to test it afterwards.
quote from his post as his states it very clearly.
Start Quote


The head seal must be replaced on your car (the ALHs have longer unloaded return spring length) in the middle of an injection stroke 'on cam'. You can either remove the quantity adjuster and verify that the cam plate has ridden up on the 4 pressure rollers, or remove the plug on the hydraulic head that is centered between the injector lines. Using a probe (like a drill bit) you can turn the pump/engine over and feel when the plunger moves in and out.

The problem when the head seal is replaced with the pump 'off cam' is this. The pump is assembled vertically, and as such the only thing holding the parts in position when it is mounted horizontally in the car is pressure from the two large return springs you saw when you pulled the QA off. When the hydraulic head is backed out, pressure on the return springs is relieved, and if pressure on them is not maximized by being on cam, parts can drop down. Usually it's a shim of thickness .7-4.5mm, between the plunger and the cam plate.

When the pump is turned over after this has occurred, the shaft is loaded in a sideways manner, and the shaft will snap as it is driven into the head crooked.

End quote.
So basically this is what happened here - there is no pressure generated by the pump and there is no in out movement of the plunger which means the shaft is broken inside and it is not turning the cam.
Although the basic job is quite simple it comes with some caveats and guys that simply tell people to do this should mention those - not just say - hey it's a simple job you cannot get it wrong - pull a DIY.
Sometimes that costs you dearly if you miss a simple step or deviate from the factory manual.
In this case the manual states - remove pump.
Place upright - turn to top of stroke.
now do the seal.
Stephan van Tonder - Jhb - Putfontein Benoni
'07 Audi S6 V10 - beast !!!!!
'05 Audi A6 3.0L TDI Avant
'07 Audi A4 2l TDI
'95 Audi 90 coupe quattro
'13 VW CC 2l tdi (repair project)
'05 Touareg v10

Perfect Power dealer. I do dyno tuning.

Return to “TDI Engines”

Who is online

Users browsing this forum: No registered users and 11 guests