Audi 80 1.9TDI Fuel pump leaking!?

[mumutley]

Hi All

Back with my old faith full Audi 80 1.9 TDI Estate

A few days ago I noted a slight smell of diesel, removed engine cover and to start with all looked OK.

Then I started the engine up and after a few minutes running I noticed a slight dribble of diesel down the side of the fuel pump!!

I have checked all the bolts from the top and they appear to be tight to me (not got torque setting for them) so I was not going to go to tight.

I have attached a picture highlighting the area were the fuel is leaking from. It looks to me like the leak is coming from between the main body of the pump and the top of it, not the black plastic bit but the join between the two alloy sections, please see pictures its leaking from were the arrows point at

IMG_3920.jpg


IMG_3918.jpg
How can I stop it? Does the pump need a overall by a professional? Can I just fit a replacement pump? (or are they coded to each engine)?

Thanks guys for your help

[zollaf]

ok, so the very top part of the pump will just lift off. the enxt part, where yours is leaking also just unbolts and lifts off and is sealed with a rubber gasket, same as the top cover. these gaskets are available from any bosch agent. the problem comes when refitting as it is adjustable and needs to be pretty exact to set the fuelling. too far one way and it will rev its head off, too far the other and it wont run, but the adjustment is literally thousandths of an inch. trial and error works and you should be able to fit it back pretty well exactly where it came from. you need to make sure the fuel metering thingy relocates into the main body, but its pretty straightforward and obvious when its off. you also need to be meticulously clean about it.
so, your choices are to do it in situ, or see if a diesel specialist will do it, or remove it and send it away to someone like diesel bob who is quite accommadating for repairs rather than refurbishment. a seal kit is about £15 to include all the seals.
if you try it yourself and it goes wrong, then you can send it off anyway, which you would do if you don' do it yourself.
if you do remove it then you just need a timing belt kit when you put it back together.
good luck, nice to see another old avant.

[mumutley]

Hi zollaf,

Thanks for the help. Were can I get the kit from? Does it have to be Audi or is it Bosch Diesel Fuel pump specialist?

From what you say, I have to remove the top section of the pump first, followed by the black plastic part, then the part were the leak is?

When removing these parts were is the adjustment you mention?

Do you have any detailed pictures of the job?

See picture detailing my questions

IMG_3920.jpg

I would like to try the job at home, I feel with a little more detail IE were the adjustment is I should be able to do this.
Also if I can help it I dont want to remove the pump as the cambelt and kit was only changed 10,000 mile ago

Thanks zollaf

[zollaf]

you dont remove the plastic bit on the side. remove the top by undoing the 4 bolts. then the next part with 4 bolts and lift it off. its on elongated holes so can move back and forth. this movement adjusts the fuelling. mark it in relation to the main pump and refit exactly where it came off. you may need to fine tune the position to get the tick over correct though. a scribed mark is best.
the kit of seals can be obtained from a bosch agent, or probably from audi, just give them the numbers from the pump, although i think all edc pumps use the same seals. oh, to save letting diesel spill everywhere, i use my oil suction tool to empty the pump when the top cover is off.

[mumutley]

Hi zollaf,

Thanks for the advice.

We have a couple of diesel specialist place's near me, I will make a note of the number from the pump and give them a ring in the next day or.

I will keep you posted

Cheers

[mumutley]

HI all

Is this the repair kit I require? Audi A3, A4, A6, 80. 100 diesel pump repair kit | eBay

[zollaf]

i should say it is. although if you are wanting to run veg oil, i think diesel bob sell the vitron seals which are better with veg, but those in the link should be fine.

[mumutley]

i should say it is. although if you are wanting to run veg oil, i think diesel bob sell the vitron seals which are better with veg, but those in the link should be fine.

How do I contact diesel bob? (I would rather have products that come recommended ) thanks zollaf

[zollaf]

just google 'diesel bob' he is actually quite a large company even though he sounds like an old boy working out of a shed.

[mumutley]

just google 'diesel bob' he is actually quite a large company even though he sounds like an old boy working out of a shed.

Certainly a little more than "old boy working out of a shed"

I will get the seal kit ordered over the weekend