High pressure fuel pump refurb - diesel

[JMW]

Hi,

So the clutch in the 75 diesel went and I am having it sorted next weekend.

Started the car a few weeks ago to keep it ticking over and noticed a diesel leak - high pressure fuel pump is leaking!

Ordered the o ring repair kit and special tool to remove it, got it out today and one of the screws holding the shaft in won't come out, going to get the impact driver on it to get it out but wanted to know if anyone knew where I could get a replacement screw as I'm not sure it will go back in and need to get it sorted this week if possible.

Regards

Jon

[Arctic]

Hi Jon.
Personally from my own venture s into replacing the seals etc in the HPFP, i found out that the larger O-ring never needed changing, so if the bolt is really stubborn i would leave well alone.

1

2

However i changed them over seeing as i had already took the shaft out.
3

Changed the main seal as that was damaged.
4

Usually it's the ones in each chamber that need doing.
5

6

[JMW]

Turns out the pump was missing an O Ring, see photos attached which may have had something to do with the leak, although I have been driving it for several years so not sure why it only started now. I'll get a spare screw from somewhere as I want to make sure all the o rings are where they should be.

Pump must have been off before?

Regards

Jon

[Arctic]

Hi Jon.
I think i sent you a couple of photos regarding that larger O-ring on the regulator, i have a theory that they over time perish to nothing and that is why sometime you find black goo on the tip of the metal filter.
1

2

3

4

From your photos it looks like your has been leaking for a while.

[JMW]

Hi Arctic,

Thank you for the photos / info and yes quite possibly been leaking a while. I have managed to get a spare HPFP as I was not able to get that last bolt out, its completely rounded, and I wanted to replace everything just in case as it is quite tricky to get the pump out.

That way I can get the bolt out when I have time, rebuild it and it can be ready for when the next one goes.

Regards

Jon

[vilas66]

Leak is not from the main shaft. If the pump leaks from the main shaft the diesel will contaminate engine oil hence You will see an increase in oil level. If pump leaks, then the culprit is one (or more than one) of the heads of the HP pump (3 heads, see the good pictures provided by Artic.) For this jobs I would suggest a professional set of torx, better if "T" ones. Rounding torx usually means low quality spanners. It's an easy job lots of videos but takes time.
Hope this helps.