Td4 injector pump leak repaired

Hi all,

I had a small leak from the injector pump top cover back in January and waited untill it got a bit warmer to remove and overhaul the pump.
I removed and overhauled the injector pump and refiited over two days last weekend and I am glad to say no more leak.
It was quite easy to remove and overhaul the pump with a seal kit from bosch as long as you have the BMW pump shaft remover tool, I got mine from ebay.

It was a bugger to get the auxiliary drive belt back on using a 24mm ring spanner on the tensioner pulley by my self but got there in the end, it realy was a two man job, one to hold the tensioner back and the another person to fit the belt.

If I can be of any help to any one trying to do the same job just let me know, I just followed rave.

I am off to get a large glass of beer :beer2:

A great result then, no more diesel leak and saved enough of the hard earned to buy a satisfying beer afterwards!

I dropped a 12 mm socket down if that area today, it went behind the Injection pump, seen it just balancing there, tries to grab it, then it dropped down some where and disapeared???

I had all the bottom covers off looking for it.............where its gone I have no idea, I hope it does`nt show its face when i`m miles from home...

jedi said:

I dropped a 12 mm socket down if that area today, it went behind the Injection pump, seen it just balancing there, tries to grab it, then it dropped down some where and disapeared???

I had all the bottom covers off looking for it.............where its gone I have no idea, I hope it does`nt show its face when i`m miles from home...

Click to expand...

Hi Jedi,
I dropped the manifold bolt down the same area a year or so ago!!!
I was lucky I fished with a small magnet on a wire for hours and then out it poped.
Hope you like fishing?
The only other way is to remove the pump and I dont think you would want to do that would you?

Chaser said:

A great result then, no more diesel leak and saved enough of the hard earned to buy a satisfying beer afterwards!

Click to expand...

Hi Chaser,

thanks for helping me locate the leak back in January.
Found a o ring perished inside the top cover, replaced all seals and o rings cost about £11 for a complete seal kit from Bosch Plus the shaft removal tool about & £30.

TD4&ABIT said:

Hi Chaser,

thanks for helping me locate the leak back in January.
Found a o ring perished inside the top cover, replaced all seals and o rings cost about £11 for a complete seal kit from Bosch Plus the shaft removal tool about & £30.

Click to expand...

You did well, a diesel specialist would have charged several hundred quid but worse still the robbing stealers would no doubt have flogged you a new HP pump plus fitting at god knows what cost!

TD4&ABIT said:

Hi Jedi,
I dropped the manifold bolt down the same area a year or so ago!!!
I was lucky I fished with a small magnet on a wire for hours and then out it poped.
Hope you like fishing?
The only other way is to remove the pump and I dont think you would want to do that would you?

Click to expand...

Tried the magnet on a bamboo cane, but it dropped further down, and disappeared. The problem with the magnet is it sticks to every thing on its way down, but if you managed to fish the bolt out, I may give it another go.

And no I don`t want to take every thing apart to find a 50p socket. :doh:

O and it was the left hand side manifold bolt i was tightening up, I then lifted my extended wrench and bar out, only to hear the socket pop off and fall down into the abbis..... needless to say the whole manifold had to come off again, but still no sign of socket.......

Its got me wondering what else is lost down there....:confused2:

Hello i had/have the same problem with my pump, i bought the tool and replaced the seals, but it still leaks from the top cover, as soon as i turned ignition it started to leak, i started then the engine and it stoped. I then tightened accessible screws a bit more, and now it leaks again even when the engine is not running....

Is there a way to put those seals in property ? The problem was with O rings, they were perished, I inserted the new ones into the hole and then closed the cover. Now i think that i should of put O rings on the pole that is on the cover and then screwed it into the pump...

oh dear...will have to do the job again....

cheers

Great info on your repair. Would like some assistance with a similar rebuild kit for the bosch pump I've no dealers around all the way in Barbados. Can someone be so kind as to recommend somwhere i could give a ring or even sell me one.