ALH TDI VE pump leaking - question about seals

Background:
My fuel injection pump is leaking. Diesel fuel is constantly leaking out - by the way, that was the reason for the premature failure of my alternator.
I went to VW early today. They couldn't find a replacement part in their AKTE system. They only had the complete pump. The master technician advised me to visit a Bosch service center on Monday, as the pump is made by Bosch. They also have a pump testing rig.
A pump was replaced by the previous owner, and VW covered 100% of the cost because it happened shortly after the first year.
The master technician at VW asked if I had filled the tank with biodiesel - of course, I hadn't, but the previous owner had used biodiesel - I absolutely hate that stuff .

Here's the image in a larger size.
http://img20.exs.cx/img20/609/Pumpegro.th.jpghttp://img20.exs.cx/img20/8228/Pumpeklein.jpg


Questions:
First, it was dripping quite a bit. The four screws on the component where the two arrows are pointing weren't tight. However, even after tightening the screws, it still dripped.
Once you loosen and unscrew the four screws a bit further, you can see two blue seals and a large number of connectors under the cover.
Can the connector be pulled out? I could only pull the cables out about 5 mm. How can I disconnect the cables from there? Or am I breaking something?

Hi,

Just out of curiosity, did you happen to have filled up with biodiesel?
Unfortunately, I can't offer much advice on how to seal a pump, as I haven't had to do it myself. However, I've read that such attempts often end in failure. 'Those of us who are experts in pumps can probably write more about this.'

I personally haven't filled up with biodiesel, but the previous owner did. When I got the car, the tank was full... with biodiesel. He said he would alternate between biodiesel and regular diesel, depending on what was available. He's been using mostly regular diesel rather than biodiesel since he got the new pump.


It probably still caused enough damage.

Hi,

If the soup only comes from the electrical connection cable, then it looks good.
Approximately 30cm away from the pump, there is a connector.
Perhaps you can simply slide the new seals over the connectors and cables.

Best regards, Rainer.

That sounds so familiar to me...

That sounds so familiar to me....

'Me too, mine had a leak in the same spot.'

How about sealing it again with biodiesel? I read about that somewhere else. It should work.

Sealing with biodiesel No, thank you. That stuff won't even come near my car. The supposed savings are a joke, because the increased fuel consumption negates the price advantage, and it also smells bad. Then, if at all, the new diesel engines with GTL additives would be a better option.


I read something in another post about seals that are black and made of rubber, instead of the original seals which are blue.

In my case, the sealant is green, not blue.

I hope all the seals are available for purchase, including the ones in the top lid and the ones for the connection cable. Or


It looks like this now, but those familiar with this might already know. We've removed the caps, and there's probably no warranty left. Besides, the other pump was installed by VW over 3 years ago. And VW immediately said, 'We can't' send it to Bosch for repair, so we'll just buy a new pump.

http://img55.exs.cx/img55/6568/IMG_1176.th.jpghttp://img55.exs.cx/img55/92/IMG_1175.th.jpghttp://img55.exs.cx/img55/9443/IMG_1180.th.jpg
@Bonze: What happened to you? Did you also experience a power outage? What did you do?

Hello Alex,
you can read more about it here:

/viewtopic.php?t=6447&highlight=bonze
/viewtopic.php?t=6383&highlight=bonze

Unfortunately, it wasn't just a story for me!

Wow, quite a few issues there.


I just called our BOSCH service department because of the leaks.

You can buy the black one for the lid separately, but apparently you cannot buy the oval and the rectangular green ones from BOSCH; you would have to buy a new quantity control system.

I already read this one on Saturday.
HI!!

You can get the O-ring directly from Bosch. Depending on the workshop, they sometimes charge an outrageous 5€ for it, even though it should only cost around 2€. However, I didn't get the original O-ring, but one made of rubber. I still want to use biodiesel.



Best regards,
Thomas

Okay, here's the translation:

'Now I'm wondering where I can get the O-ring from Katushchuk. Apparently, Bosch doesn't sell them, according to their phone support.' No information, not even about the normal ring.

Hello Alex (a beautiful name, by the way )!

Black O-rings/seals are made of NBR rubber and therefore should not be suitable for use with biodiesel or oil!
The green seals are made of Viton and are therefore much more chemically resistant. The compression set of Viton seals is almost negligible.

Therefore, my advice: If possible, install the Viton seals (green) right away, and you'll be done with it!

Regards,
Alex.

Well, the problem is that the green seals apparently aren't sealing properly anymore, and Bosch told me that they don't sell those. I don't necessarily need the black ink; it seems okay.

Diesel is leaking from the location marked with the red arrows.
First image above.

You've won the grand prize...

'Unfortunately, those seals are not sold individually as spare parts; only the complete valve assembly is available.'

CU Gremlin.

Yes, perfect... then I must have done the right thing intuitively.

A very polite letter to the manufacturer, requesting information about where this cheap item can be purchased and who the supplier is. I still believe in miracles, I know .


Anyway, that nice gentleman at Bosch probably wasn't telling me nonsense when he said I would need to buy a complete flow meter system.


Can someone tell me what this is supposed to be? The three seals could be easily removed and replaced without any adjustments, but they are not available for purchase .

Hi,

The issue is that these O-ring parts are custom-made form pieces. No manufacturer of such "low-value items" will sell you a part like that, even if you get a hint about it from Bosch. In such cases, the solution is to purchase suitable O-rings in a round shape with the correct diameter (length). Installing them might not be a piece of cake, even with such clear geometries and easily accessible installation locations, but it should be achievable with a bit of ingenuity and some grease. You can determine the required diameter most easily by loosely sliding the O-ring onto a suitable conical turned part. Since I currently have a binocular with conical optics in my field of view: if necessary, it can also be used for that.
The key dimensions of an O-ring are the cord thickness (which is the diameter of the material) and the inner diameter. By the way, the manufacturer determines it in the same way if you provide them with a sample.
http://www.busakshamban.de/cms/Products/Base gaskets
Here's a manufacturer that produces these seals, and they also sell them in "small quantities" here in Vienna.
These O-rings are also available as cords and can be joined to create custom shapes using appropriate adhesives (by bonding the flat surfaces). This works excellently, for example, in mold making, where NBR cord material is used to seal cooling holes.

Best regards, Robert.

Hello,

Sad story, and I'm affected by it too. Someday, I'll have to replace the sealant on my ESP as well.

What about a professional mechanic from Hamburg who also runs an online store on the side? I've contacted him before; he seems like a nice guy.

dieselsend.de/

He used to sell ESP gasket sets made of Viton for biodiesel applications, but unfortunately, he doesn't offer them anymore.
He has complete sets of stamps, but it might also be possible to sell individual stamps.

Best regards, Georg.

@Georg-TDI:

Henzo from Dieselsend already has quite a lot, but when I look at the pictures of his sealing sets, I can't find the seals that DerAlex needs (which are green in the photo).

Regards,
Private.