High pressure pump refurb
 

So..

Just discovered that my high pressure pump is peeing diesel all over the undertray.

Its got to the point now with this car, I have replaced so much stuff that its cost me thousands, and its now having an effect on my mental heath with all the stress and hassle its caused me.

How hard is it to remove the pump with the special tool? is there ANY scope for screwing it up and having the sprocket drop?

Also, how hard is the seal replacement in the pump itself? Do you need a manual for this?

I was going to purchase a 2nd hand one off ebay, until I realised, that anyone who rebuilds these pumps does so in a clean environment, and a filty pump off ebay has the potential to have unlimited amounts of crud inside where the breakers didnt cap the inlets/unions.

Obviously I cannot afford a new one, or afford for a garage to do this, but I could stretch to a local diesel specialist to rebuild the pump itself, what sort of cost could I expect to have to take?

I cant let this car go for sentimental reasons, as I have a lot of great memories in her, so I have to try and keep it going as long as I can.

Cheers fellas.

Sorry to hear your latest problems, there are plenty of traders on here who can be trusted and know these cars and would surely take the pump off the car with care for you and no doubt be able to advise on removal too.

Not sure the cost of a rebuild you would probably have to call a specialist to find out who may need to see it first

Whatever you decide , keep the faith !

Take a look at the Bosch web site, they will list companies that will refurbish it for you if you take it off or will take it off and refurbish it but that's a lot more. I think the pump is Bosch, apparently fairly common they leak

not sure if this link is any good http://www.boschcarservice.co.uk/

macafee2

PM Seancar, he'll have one and will take care when removing it. I posted a link to a new item in your other thread, but to be honest a 2nd hand one will do the job fine as they don't fail too often.

Treat yourself to one of THESE

And one of THESE

Now the job itself is straightforward enough, before disassembling the pump clean it thoroughly with a hard surface cleaner ensuring the ports are plugged to prevent dirt ingress.

The seal kit I linked to, provides nice pictures of what you will expect to find upon disassembly, and will be more than adequate to guide you through the job ;)

You will find there are conical crush washers in the kit, only about 5mm in diameter, which provide the seal for the high pressure discharge side.

These must be located very carefully when reassembling, and I have found the tiniest smear of vaseline is the best method of doing so ;)

Only work on one cylinder head at a time, take pictures as an aide memoire, and remember cleanliness is the key to success ;)

Working carefully and methodically, and you will be fine..... it's certainly preferable to paying circa £600 for a remanufactured pump.

Hope this helps

Brian :D

Hey thanks for that Brian, its really useful.

How do you know which way round the little conical crush washers go?

Brian that tool is a lot cheaper than I bought :} I ordered the O-ring set a couple of weeks ago for my spare HP fuel you just never know when you might need it, I still have to add the new seals etc something to do in the dark nights ;) cheers Arctic

https://www.ebay.co.uk/itm/253170086806

I just bought the shortened LASER version, hope to have car running again after the weekend.

Any special requirements? Like Torque settings for the bolts which hold the heads on?

You will see when you take it apart Ross, but the instructions supplied with the kit are pretty comprehensive ;)

It looks a bit daunting, but it's straightforward.

The torque for the head bolts iirc 25Nm, but the trick is to tighten them progressively on the diagonals at first, then in rotation later making sure it's pulled down evenly :)

Brian :D

I was going to go with a genuine Bosch service kit, Im hoping that will still come with instructions?!