Disco 1 Injection pump fuel leak

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Gazbo

Well-Known Member
1998 Tdi 300, just returned from a 1800 Klm trip, travelled some very rough roads and tracks, deep water crossings etc.
Since returning home I have found that there is a small amount of diesel leaking from the rear end of the injection pump from what I would call the "head", a fairly solid cast steel block that the lines to injectors fasten onto. The leak, very slight, seems to emanate from the interface between that solid cast "head" and the alloy body that it is bolted to.
Anybody able to help with prior experience/knowledge of this leakage, I'm assuming that these two parts employ "o" rings or other seals, I think I could buy stuff for the Bosch VE pump from a local diesel service shop, I have previously bought and replaced a throttle shaft and top cover seal.
Is it possible to carefully remove the back end of the pump and replace the necessary seals without removing the pump from the engine.
Had a quick search here but keeps coming up "not found", help!..............anyone.
 
Think you can loosen the bolts holding the 'head' to the body then slide the now ring over, there's threads on tdiclub forums (more vw related but same type of pumps, I'll see if I can find a link when I'm home this evening from work as I'm on my phone...
also if I remember it's common to leak if you've used veg oil as it's slightly 'thicker' than diesel)

There's 'O' ring kits on egay

Rich.
 
You MUST make sure the pump is on full cam before you attempt to progressively and evenly loosen the bolts just enough to allow head to come out so O'ring can be changed. Have one bolt in place at all times to stop head from coming out completely. Work O'ring on then put a bolt in to hold head before removing holding bolt to allow O'ring onto head completely. Lubricate O'ring and tighten bolts evenly to push head back into pump. Ensure O'ring is not nipped or damaged in any way. If pump is not on full cam you will lose the thrust spacer from between cam plate and piston.
 
Many thanks to all contributors, for the "good oil", hope soon to have to hand the step-by-step information needed to cure the leakage, and it still is leaking.....rather unfortunately............all part of the fun of ownership.
 
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