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Righto, so I been running my golf on straight veg for about 500 miles now - and the pump head seal has started to leak a fair bit. It did "weep" a touch before with diesel, but that evaporated mostly before it hit the floor - obviously veg oil doesn't. I've read that you can change the pump head seal with the pump still on the vehicle by removing the injector pipes and carefully removing the head, but theres a risk of the insides all dropping out and firing all over the place. So then, I read about a kit from the USA that comes with a super stretchy seal and a longer bolt that allows you to just slide the head off a bit and stretch the new seal over the head:  But this is advertised as for TDI pumps - mine is just a 1Y non-turbo in a mk3 golf. Are the heads the same size? has anyone took the head off completely? |
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after playing with a few bosch pumps in various guises... I'd personally never attempt it with anything less than having it clamped down solidly in a vice.
In the mech pumps, there are two little springs which would fall down if you tried this method, for starters...
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You're like a crazy backyard genius! |
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you can fit the head seal with the pump on the car I sell the seals you need on ebay they are viton and unlike the Bosch seal it stretches and goes back to its original shape instantly they are also veg/bio proof if your fitting the seal with the pump on there car its a delicate job you need to first remove the top from the pump and and injector pipes etc so you can see into the center spindle if you rotate the engine by hand you will see a cam inside move in and out you need to stop this so its as close to the head as possible to keep the pressure on the springs once your here you can remove the head screws keeping just the top left and bottom right screws remove these slowly till you can just see the seal as in your picture I bought a cheap pound shop dental kit with a mirror and pick and it was ideal for removing and refitting the seal. Instructions and seals are avaiable at www.headseal.com if you need any more advice drop me a pm and ill help you out |
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Last Edit: Jan 4, 2019 16:39:55 GMT by topghia
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Aah, if only you'd have posted this a bit earlier, doh! I've fitted another pump now! I might still have a seal off you and fit it to my old pump at some point though.
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Jul 15, 2013 10:28:38 GMT
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worth having a spare whats car is this for? i was in the same boat as you i fitted my engine did about 600 miles on svo and seal went i bought the bosch ve reseal kit and read that the bosch seal loses shape if fitted over the head(which it did i tested it against one of my seals)
the nitrile seals drop back to the same size instantly i also coat them in red rubber grease so fitting is easy
but tbh id still attempt this method of fitting even with the pump off to save things getting complex and also a learning curve for the future
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Jul 15, 2013 12:57:16 GMT
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also the tdi pump is identical to the n/a pump apart from the upper gaskets for the turbo grubins at the top
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Jul 15, 2013 12:59:50 GMT
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So then, I read about a kit from the USA that comes with a super stretchy seal and a longer bolt that allows you to just slide the head off a bit and stretch the new seal over the head: longer bolts are not needed the stock bolts are plenty i don't know why they would be pushing this at all |
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Jul 17, 2013 10:06:08 GMT
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marketing - if the customer is made to think it's better, they'll buy!  |
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You're like a crazy backyard genius!
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true it can be a daunting job so something like this would work to boost sales for them
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Colonelk
Posted a lot
Posts: 3,740
Club RR Member Number: 83
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Jul 19, 2013 16:04:16 GMT
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just a FYI, myself and Hardcore did this on the pump on his Audi 1.9tdi (1z? I forget) wasnt "easy" but with care we moved the head out and replaced the seal. No internal kerplosion!
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Jul 22, 2013 14:27:24 GMT
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if it has an electronically controlled pump, they don't have the two little springs that can cause all the issues |
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You're like a crazy backyard genius!
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Sept 28, 2013 18:14:05 GMT
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sorry to bump this topic but how far can the pump head be pulled off before anything goes wrong, this is on a tdi electric pump. Ive just bought one of your seals topghia
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Nov 26, 2013 14:45:53 GMT
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sorry i havent got back to you sooner hopefully you contacted me via ebay basicly you screw the head out just enougth to do the job. if you can get the old seal out thats as far as you need the new one should slip in just as easy with help from the red rubber grease i coat the viton seals in
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Nov 26, 2013 14:49:09 GMT
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cobblers picture shows the seal clearly. ive changed many bringing it out this far without problems aslong as you position the cam outward as in the video link
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Tepper
Part of things
Posts: 381
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Oct 29, 2017 21:55:21 GMT
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Dragging up an old thread I know but have just managed this successfully with the pump in situ on a Peugeot 309 XUD engine. Instead of taking the top of the pump off I found it easier to remove the bolt in the middle of the pump head and use a drill bit to see when the plunger was at it's furthest point. The pump's still leaking, but the process itself worked fine. Any ideas as to what could still be leaking? It looks like it's coming from that area of the pump.
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1989 Peugeot 205 GTi - stolen!
1983 Mazda RX7
1968 Rover P6 - also stolen.
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Tepper
Part of things
Posts: 381
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May as well update this, it turns out I had managed to put a slight nick in the head seal on replacement- be careful the head goes in nice and square, but the process itself is sound and I managed it a total of three times without the pump pouring it's spring-loaded guts out all over the engine bay. The pump was still leaking after this, the leak was traced to the timing plug or hydraulic head plug o-ring, seen here:  Pretty knackered. This lives in the middle of the pump head and is pretty easy to get out after loosening the front two injector lines. The o-ring size is 30mm ID x 2.5mm cross section for anyone who needs to buy one - I couldn't find the size anywhere. I went for viton so it would be resistant to veg/biodiesel. The pump is now leak free. Result! If anyone needs to attempt similar leak prevention I have 4 spare o-rings and a tool kit that includes the 3-point 26mm socket needed to remove the timing plug. I'd be more than happy to stick the tools and an o-ring in the post for a couple of quid and a deposit  |
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1989 Peugeot 205 GTi - stolen!
1983 Mazda RX7
1968 Rover P6 - also stolen.
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Jul 25, 2018 14:58:37 GMT
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Still got these bits mate I need to do mine? |
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Tepper
Part of things
Posts: 381
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Jul 26, 2018 19:24:45 GMT
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Yes indeed, will send you a PM.
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1989 Peugeot 205 GTi - stolen!
1983 Mazda RX7
1968 Rover P6 - also stolen.
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Jan 20, 2019 16:18:13 GMT
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Hello guys I have just setup a discount code for my fellow retro riders. Head over to www.HeadSeal.com just enter RR10 at the checkout to receive 10% off your order aswell as free worldwide postage. |
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Jan 11, 2021 13:00:05 GMT
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May as well update this, it turns out I had managed to put a slight nick in the head seal on replacement- be careful the head goes in nice and square, but the process itself is sound and I managed it a total of three times without the pump pouring it's spring-loaded guts out all over the engine bay. The pump was still leaking after this, the leak was traced to the timing plug or hydraulic head plug o-ring, seen here: Pretty knackered. This lives in the middle of the pump head and is pretty easy to get out after loosening the front two injector lines. The o-ring size is 30mm ID x 2.5mm cross section for anyone who needs to buy one - I couldn't find the size anywhere. I went for viton so it would be resistant to veg/biodiesel. The pump is now leak free. Result! If anyone needs to attempt similar leak prevention I have 4 spare o-rings and a tool kit that includes the 3-point 26mm socket needed to remove the timing plug. I'd be more than happy to stick the tools and an o-ring in the post for a couple of quid and a deposit |
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