Diesel injector pump seals

[hiho]

I had some spare time this morning, and a spare injector pump and as my car is leaking fuel, i decided to investigate seal replacement.

Firstly, clean the pump thoroughly, I assumed that my pump was as corroded inside as out so i didnt bother cleaning it. Big Mistake. Internally the pump was spotless, now it needs a complete rebuild as bits of dust, corrosion and other crud entered the pump.
http://www.vwwatercooled.com.au/forums/images/imported/2006/07/IMG_0751small-1.jpg
To remove the top cover, remove the accelerator lever from the accelerator shaft, noting its alignment on the splined shaft. Undo the four cover screws, tap the cover to break the seal, push the accelerator shaft out of the cover as you lift it off. This gives you access to the accelerator shaft seal, which is an o-ring type.
http://www.vwwatercooled.com.au/forums/images/imported/2006/07/IMG_0754small-1.jpg
Its dimensions are roughly 11mm od, 7mm id and 2mm thick.
Next i attacked the cold start shaft seal.
http://www.vwwatercooled.com.au/forums/images/imported/2006/07/IMG_0755small-1.jpg
Simply remove the lever arm (noting its position on the shaft), two cover screws, remove the cover and shaft, press the shaft out of the cover and there is the seal, another o-ring of the same dimensions as the accelerator shaft seal.
http://www.vwwatercooled.com.au/forums/images/imported/2006/07/IMG_0756small-1.jpg
This is the cold start shaft cover seal, another o-ring. This seal doesnt have contact with moving parts and probably wont be leaking, however, its dimensions are 32mm od, 26mm id and 3mm thick.
I have not yet disassembled the pump to acces the input shaft seal (bit daunting). Has anyone had to replace this seal before?
All of these seals should be available in Viton or equivelant ULSD tolerant compound.
Any comments are welcome. Also if anyone wants detailed photos of the internals of the pump before they attempt any repairs on their own pump, I am happy to use mine for this educational purpose.
Matt

[gtimk5]

Excellent pics and explanation HiHo. Good on you, thanks, Andrew:)

[Golf Loon]

Yup thanks for sharing the knowledge. Keep it up

[brackie]

Sorry it's taken me so long to reply to this post :( I've been flat out and neglecting my job.

Mate, you're one of the few who are courageous enough to go inside a pump! Well done!

If you intend using this pump on your car you will need to get it a lot cleaner than it is. The dirt that I see in your photos is 10,000,000,000X more than enough to damage the pump and injectors. If you intended to use the pump again the injector pipe unions and banjo fittings should have been plugged and the pump put in a parts washer for as long as you could afford to keep it running, then air blasted and dried before removing any of the cover plates or housings.
The "top cover" (hydraulic governor housing) seal and the bronze bush in which the throttle shaft runs are the most I've ever had to replace on a VE pump, but that was in the days before ULSD and before I began using a little canola in the tank. Oh, if you replace the bush remember to "Loktite" the new one in.
Vitron seals should be available. The core of the pump s a little trickier to disassemble and you should make very careful note of parts as you remove them. If you reassemble with care and tighten everything back to the torque at which you removed it you should be able to replace the rotor seals without difficulty. Somewhere I have diagrams of the internals of the VE pump but I'm too busy atm to search them out and scan them. Later perhaps.
Also, remember to wash the internals of the pump in clean diesel as you assemble it. Even the smallest chip off a screw head or a hair from your head or arm can be enough to cause problems.

[adrianglock]

This is a common problem the rubber might have been shrunk due to heat or changing temperature the tendency is the seal becomes brittle.

[jets]

Well done , I really should do mine, it's leaking too. Here's a link to an assy procedure I found some time ago.
VWDieselParts.com :: View topic - VE injector pump assembly pictures. (http://www.vwdieselparts.com/forum/viewtopic.php?t=6694)
Just reread the original post, over 4 years ago, still my link may help someone.