leaky throttle shaft

Click "Pump Land" at my site here for pics.
mysite.verizon.net/vzevceex/


I started this doc a while ago, so it may need some revision.

Remove the air filter, intake tube on the intake manifold and fuel filter assembly.
Clean the pump real good with gas or break cleaner and a brush.
Loosen or Remove all the lines from the top of the pump (one is clamped to back of top so leave that clamped, but remove clamp to intake manifold bolt tough one to get off) and throttle cable.
On some pumps the top of the throttle shaft has no markings. You will need to get a dremmel grinder and make one that lines up with another one you must make on the throttle arm BEFORE you remove the nut springs and throttle arm. Remove the fuel feed at front of pump and rotate it up out of the way.

You will need to buy or steal an extra nut for the calibration screw to double nut it. Make sure the nut real snug against the one that is already there. Now put a boxed wrench on both nuts at once and push down to loosen the whole screw and nut assembly and remove it. Now if every the top should be ready to pop off (may need to tap) leaving the throttle shaft in the pump.
Change the o-ring and put it back together.

Good luck!

Dave


Bad news is

Now the 4 - 5mm allen head screws (you may need to smack them with a pin and hammer on top to loosen them I use a 3/8 drive extension and hammer)

pm me
dieseldavo came up with this fix.
i have a pdf file with photos.
mysite.verizon.net/vzevceex/id2.html
pump does not need to be removed.
if you have power stering, it will need to be removed.
cc

i finally fixed the leaky throttle shaft, easy job once i got the power steering out of the way.
this is the first injection pump i've worked on.
i'm glad i had extra nuts to double nut the adjusting screws. i also scribed the throttle assy, to ensure a good alingment.
after purging the injectors, she fired right up. i needed to slow down the idle. about 500 rpm.
sure runs smoother now.
now maybe now i can get a few other projects completed i've been putting off.
cc

Click "Pump Land" at my site here for pics.
mysite.verizon.net/vzevceex/

The number for the o-ring is on a Bosch card in the picture.
blueridge diesel has them.

www.blueridgediesel.com/

i bought mine through the local diesel repair shop, pakage of five. should last me untill i get a million miles on the engine.

when you remove the cover with the throttle. mark the placement of the throttle shaft and the plate that is held on with a nut. then remove the nut and the shaft will slide out of the cover toward the inside. after the shaft is out, you will see the o-ring.

i had to make up a custom allen wrench to fit the rear engine side screw, as i didn't have a small swivel allen head driver.

After replacing all the o-rings I could get to without removing the pump, it turns out my leak is a bit harder to fix. It's leaking from the back end, between the main lower part of the pump and the section where the fuel cutoff sensor/switch is. I realized this after working on it and seeing the leak while bleeding the system. Diesel Davo's photo third from the top shows this section. I believe this is called the hydraulic head of the pump, and I think the pump needs to be removed because there are some return springs holding the pump distributor in place. Does anyone have any suggestions or know where to get an extractor (part # 49 SE01 157). I'm thinking I might have to give up and take it to a mechanic, but I'm open to suggestions. I did find this site showing the assembly of a similar pump with lots of photos (http://www.vwdieselparts.com/forum/viewtopic.php?t=6694) for those interested.
Thanks again.
-Troy