TDI300 injector pump rebuild instructions

I just coverted my 1996 disco diesel to 100% palm oil. I live in Brunei so its hot and I figured the viscosity would OK. After three days of running, a leak has developed at the injector fuel pump. I checked the Land Rover manual, but it does not go into injector fuel pump rebuilds.

Does anyone have a suggestion on where to get info on the pump thats stock in a 1996 TDI300 and where to get parts and instructions on how to rebuild these?

Don't even try to do this.

You should ascertain exactly where the leak is, because there shouldn't be any chance of a leak if the injector pipes and fuel pipes are secure, and the top cover sitting nicely. It is almopst surely something LOOSE and there's almost no chance that stripping the pump and rebuiilding it will be a good idea. What is INSIDE that pump does not leak!

The ONE thing you might attempt (if you are SURE it is leaking) is the gasket under the top cover of the pump, BUT BUT BUT ...... be aware that the whole mechanism is like a clock inside, and is arranged with all sorts of little springs and levers joined on all over the place, including between the lid and the rest of it.

I very much doubt if you will easily find a service instruction for the injection pump. Before you try the job it would be a good idea to find another pump off a scrapper and try the job out.

CharlesY

As charlesY says "BEWARE"

Specialist job! I once got lucky with a bosch pump on an Audi that was leaking, it was just an o ring on a side plate that had failed due to crap in the pump,blocking and blowing the seal.Got the seal from a diesel pump specialist for a few snakes as Audi only sold the whole pump

Clean the pump very thoroughly then run the engine so you know EXACTLY what is leaking before you do anything else.

CharlesY

Here's a pictorial guide of a Bosch VE pump used on Peugeot 205 (aspirated diesel): Bosch VE injection pump , same thing on a forum, translated from french: Complete Pump Dissasembley w/Pics! (NOT DIAL UP FRIENDLY!!) (dial-up users warning: >13 MB of pictures!) and here's the original article on a french forum: Réfection pompe à injection Bosch, explications [Photos] (same warning).

Here's where you can find some Bosch diesel service shop in the neighborhood: Sarawak, Malaysia.

Thank you very much for providing me with the detailed pump refurbishment guide, the location of Bosch agents and a workflow to assess the problem.

I plan to go to MIRI this weekend to see if I can get the oil rings, seals,...

Again thanks

Which pump is it?

The most likely source of a fuel leak is the little O-rings where the control spindles fit into the lid.

I have done these myself on a Lucas CAV pump, and it was easy enough.

You would not need to take the pump off the car ... just clean it very carefully first, and set about lifting off the lid.