Fuel Injector Leak: User Review & Troubleshooting

On December 24th, my wife's Passat started smelling like diesel - ESP between...
The pump housing and pump head are leaking. This is likely due to the vehicle being frequently operated on biodiesel.
As soon as I saw that it was being used for driving, I thought that would be ammunition for the anti-biodiesel lobby.
is. That's completely wrong; both the pump head gasket and the seals are...
Weighing stations varied considerably in terms of their dimensions and the materials they were made of.
perfect condition, but the seal of the pump head was flawless.
Assembly damage. It's a shame that it lasted for 6 years.

'Great! This is a Bosch poetry set (part number 2 467 010 003 - €11.14) and it fits all newer models.'
VP37 pumps - does not include a shaft seal! It can be difficult to obtain these quickly.
'It's tough to stay calm and not commit murder when dealing with the comments you receive in various workshops!'
'It can't be repaired,' 'They won't be able to fix it anyway,' 'This can only be done at the factory.'
etc.!

After taking various readings with VAG-COM (e.g., throttle valve travel)...
(Engine running/ignition on/engine cold), as well as fuel injection quantity and throttle valve position.
While idling at 50°, 70°, and 89°, it then proceeded to the main task. Before removing the ESP...
I marked the intended mounting location of the pump on the console to avoid any major issues during installation.
to have a dynamic injection timing check. The next problem was the drive gear of the ESP: it was stuck tightly on the cone, and of course, there was no flat surface to allow for adjustment.
Jacked up the front of the car and placed it in service position, then used a standard two-arm puller.
Slightly modified and with some pre-tension applied to the gear, a gentle tap with the plastic hammer, and the gear came off! Caution! Be sure to place a cloth underneath so that the wedge doesn't fall into the timing belt housing!
After that, the expansion was straightforward!

Secure the circuit board in a vise (using plastic jaws and avoiding excessive clamping!).
Adjust the quantity using a gauge with a pointed needle against the pump housing at 4 to 5 points.
markiert und ausgebaut. Die Sicherungsschraube habe ich mit einem Schraubenzieher entfernt nachdem ich mit dem Dremel einen Schlitz eingefräst hatte. Later on.
replaced with a standard Allen head screw M6x60.

To seal the pump head, it is not necessary to disassemble the flow control unit.
However, I wanted to replace all the important seals because at that time I didn't know anything about...
I knew about the actual damage to the seal, and besides that, I was curious.

After that, I determined the torque for the pump head screws (approximately 10-12 Nm).
Removed the screws on the opposite side of the pump head and inserted two M6 guide pins.
Then, loosen and remove the two remaining screws simultaneously and slowly.
to prevent the pump head from tilting. It is absolutely necessary to ensure this.
to secure the ESP with the pump head facing upwards. If it is handled gently,
'It can be easily secured in a vise, which I would prefer to other methods.'

I was really disappointed with the internal workings of the pump; I expected it to be more complicated.
introduced!

No further damage or any deposits were detected in the ESP (Electrostatic Precipitator).

Okay, I reattached the point machine and tightened it according to the markings.
As long as the pump head is still disassembled, you can clearly see whether the cam...
The setpoint selector knob must be properly seated; otherwise, it can lead to embarrassing situations (see...).
Also, first the technical article by Marcello. Then, replace the pump head with a new seal (O-ring).
attach, secure with two screws, remove the guide pins, remaining screws.
einsetzen und alle 4 Schrauben über Kreuz mit 12Nm festgezogen. ESP eingebaut, angeschlossen und über den Rücklaufanschluß entlüftet (Ganz wichtig!!). Mototurned on
und mit VAG-COM die Einstellung des Mengenstellwerks vorgenommen. Because I...
The values at multiple temperatures were recorded quickly.
but it's really fiddly. You get the feeling that you haven't moved the casing at all, and...
'However, the amount of fuel injected has changed significantly. In my opinion, it's impossible to diagnose this without a diagnostic tool.'
feasible or, at the very least, extremely difficult.

Now everything is sealed and the engine is running perfectly again. Because I didn't quite get the previous injection amount right, and it's now about 0.3 mg per stroke larger.
As before, the eternal problem of low torque during acceleration remains.
from low RPM in a high gear (the engine felt somewhat reluctant and rumbly - that's why...)
(which was often used with the kick-down function) and completed. This leads me to believe that the excellent Bosch test stand...
'Even a job isn't always the perfect solution!'

My conclusion from the whole situation: A leaky ESP isn't the end of the world - provided that...
You need a few tools (patience, time, a verschandeln workbench, a vacuum pump, or...).
(with a vacuum pump, puller, and diagnostic tool). It took me about 8 hours, but I think I can do it in 6 hours now.

I'm only interested in how to replace the oil seal on ESP units with two-piece gears. My assumption is that you can use a dial indicator to measure the position of the ESP piston.
Can I use a hub? I might have to do that on my Golf someday.
I am reporting.

Thank you for this report.

Did you also take pictures of the fun so that those who haven't yet installed an ESP (Electronic Stability Program) can see what to expect?

Uploading or scanning should not be a problem.

Thank you.
m,

Hello Dieselmartin,

I don't have a digital camera, and I also didn't have any film. Plus, my scanner is broken!

But I think there are already enough pictures on this topic in the forum.
The various drawings found in different repair manuals are often much more helpful than pictures.
As I already mentioned, it takes time and patience, but then things will become clear.
Expanding the ESP almost automatically!

Thank you to you and my appreciation. Hats off – articles like this really help others. Regarding your golf question, I'm afraid I can't provide any information.
Matthias.

matthiasTDI96 wrote:

Thank you to you and my appreciation. Hats off, articles like this really help others. Regarding your golf question, I'm afraid I can't tell you anything. Matthias

I completely agree.

If Rainer approves you as an author, I think the report would be suitable for the collection of technical articles.

Slightly streamlined (e.g., without any thoughts of murder ), and enriched with pictures/drawings, I would easily give it a score of 11 points .

Hello Jürgen,

I read your report with great interest.

As I understand it, you only replaced two seals (between the lid and the MSW, and between the MSW and the ESP). Why did you then have to remove the ESP? Or did you replace all the seals, including the one between the high-pressure pump and the housing?

I recently had to replace a gasket between the lid and the main body of my espresso machine, and it was absolutely easy.

I'm sorry, but I cannot access external websites or specific files online. Therefore, I am unable to translate the text from the provided URL.

I have now acquired a complete seal kit, including the wave ring, for my ESP. I plan to replace all the seals on the ESP this summer. If you remove the pump, replacing the HD component shouldn't be too difficult (but caution, time, patience, and technical literature are essential).

Do you still use biodiesel?

Best regards, Georg.

Hello Georg-TDI,

If you re-read my post (I admit it's long!), you will...
seeing that the reason for the measure was a leak between the pump head (sometimes...
(also called a high-pressure pump!). The likely cause of the leak was...
Clearly, it's not the use of biodiesel, but rather a definite assembly error.
It was probably a Bosch part. The O-ring was installed incorrectly and was slightly...
'A portion of the circumference was worn away. I'm just surprised that it lasted for 6 years or 180,000 km; people never learn! The seals on the MST and the MST cover were...'
Certainly.

'However, in my opinion, the tolerance between the outer edge of the pump head and the...'
The ESP enclosure is quite large, which unfortunately means leakage problems are almost guaranteed.

I will continue to use biodiesel, why not? However, I have a...
I have a fixed supplier and only purchase from them because they also have a fixed price.
Suppliers (from the region)!

SMALL ADDENDUM:
The car had been difficult to start for some time, especially when it had been idle for longer than...
It hasn't been moved in a day. It's completely gone. You only see the keyhole now.
and it's running! So, even here, there's a way to let air circulate.
without any visible external leakage, and at VW Group, the entire...
Switched to ESP. Real part-swappers, but with clever remarks!

Hello.

Thank you for the excellent report; it will definitely help me with a similar task.

I have a question regarding the following statement:

ESP installed, connected, and bled via the return connection (Very important!!)

What do you mean? I haven't been able to find anything about venting in various posts on the subject.

Thank you.

Hi there,

Use a large syringe to draw from the fuel return line on the ESP until fuel starts coming out.

Regards,
A.