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  #1  
Old November 5th, 2012, 03:59 PM
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300 Tdi & dieselgeek.com

Hi all,

The head of my 300 Tdi injection pump started leaking and while looking for parts/solutions, I ran across a writeup for the VW Tdi at dieselgeek.com:

http://www.dieselgeek.com/SearchResults.asp?Cat=1873

The writeup looks like it'll work for the 300 Tdi, and several posts on other Rover forums seem to confirm this. I would like to use their seal:

http://www.dieselgeek.com/Viton_Pump.../pmp-viton.htm

I called dieselgeek.com and Alex there said he did not know if this O-ring would fit a 300 Tdi, but did say it was 55 mm. Does anyone here know if this will fit a 300 Tdi injection pump?

Thanks.
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  #2  
Old November 5th, 2012, 04:18 PM
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Matthew
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Pretty awesome, ive got this same leak on my 200tdi pump. Would be awesome if this was an easy fix
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  #3  
Old November 5th, 2012, 05:17 PM
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For $9 certainly seems like a low risk silver bullet.
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  #4  
Old November 5th, 2012, 08:24 PM
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Quote:
Originally Posted by 130Tdi View Post
For $9 certainly seems like a low risk silver bullet.
I think the risk is taking the whole pump apart to find it is the wrong size...
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  #5  
Old November 5th, 2012, 11:06 PM
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Write down all the numbers on your Bosch injector pump. Call a Bosch service center and and for a "seal Kit" or a "rebuild kit" for your pump, cost about $25 and you'll be assured of getting the correct seals.
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  #6  
Old November 6th, 2012, 08:49 AM
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Quote:
Originally Posted by Dennis View Post
Write down all the numbers on your Bosch injector pump. Call a Bosch service center and and for a "seal Kit" or a "rebuild kit" for your pump, cost about $25 and you'll be assured of getting the correct seals.
Dennis,

I wish I could still read the numbers - they're pretty much wiped. Also, I'd prefer the Viton seal.
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  #7  
Old November 6th, 2012, 09:39 AM
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Originally Posted by michael67 View Post
Dennis,

I wish I could still read the numbers - they're pretty much wiped. Also, I'd prefer the Viton seal.
F' "prefer". Insist on Viton. It's not even an option in my mind.
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  #8  
Old November 7th, 2012, 09:09 AM
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I have a spare pump off the truck (200tdi) Ill buy this kit and post how it goes
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  #9  
Old November 7th, 2012, 11:16 AM
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Quote:
Originally Posted by Naplm00 View Post
I have a spare pump off the truck (200tdi) Ill buy this kit and post how it goes
I ordered mine yesterday. I won't be able to get to it until next week though.
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  #10  
Old November 7th, 2012, 11:19 AM
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Nice! let me know
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  #11  
Old November 24th, 2012, 10:49 PM
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Good news - the seal fits and the procedure works! No more diesel puddles under the Rover.

There was some small modifications/clarifications of the procedure for the 300 Tdi:

- I removed the lift pump from the block but left fuel lines connected. This allowed me to more easily get to the inner-most T30 screw on the pump head.

- In order to remove the support bracket I removed all screws except those at the 3 o'clock & 9 o'clock position. These two remaining screws correspond to the screws in step 9 of the dieselgeek.com procedure.

- Since I wasn't sure which pump the 300 Tdi corresponded to (ALH or AHU), or even which corresponded to up or down even if I did, I bought another 55 mm screw to support both sides of the pump. I don't think this was necessary, as I removed the inner-most screw while cleaning.

- I used the Land Rover procedure for bleeding at both the filter and the injection pump.

I also followed their link to set the injection pump on-cam.

The only thing I would've done different is gone ahead and cleaned the pump head. As it was I ended up using a lot of Q-Tips to clean between the pump head and the pump body after exposing and removing the seal.

I also replaced the fuel shutoff solenoid as it had been acting up, that and me having to tear up the bolt corners to get it out. I also replaced all of the Torx bolts with Allen wrench head bolts (only thing I could find at Ace):

2 x M6, 25 mm
2 x M6, 45 mm
2 x M6, 50 mm
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  #12  
Old November 25th, 2012, 01:52 PM
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Thanks for sharing this! Very clear wright up.
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  #13  
Old April 27th, 2016, 09:10 AM
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Resurrecting an old thread . . . well on the way to doing this injector pump seal replacement, but mine's got a lot of surface corrosion on the head, and the fuel cutoff solenoid body is resisting efforts at removal.

Two questions:
1) The solenoid comes with pre-rounded corners, and it feels like my 24mm wrench is just going to finish the job. It's currently doused in PB Blaster, and I'll try again tonight. Any thoughts on how to get it off if the wrench does indeed fail me? Obviously vice grips or channel locks--anything else I might want to try? I'm going to order a new solenoid today, so I'm not too worried about damaging this one.

2) If push comes to shove, can I replace the o-ring without removing the solenoid? i.e. does the solenoid prevent the rearward movement of the head, or is it just another obstacle to overcome as you stretch the o-ring around the head?

Thanks in advance!
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  #14  
Old April 27th, 2016, 10:29 AM
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The 1st one I pulled was on a 524td with 6 ports to work around. Did it with a crescent wrench.
The slightest "fuzz" will keep the plunger from not working correctly, extreme cleanliness is required when reassembling.
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  #15  
Old April 27th, 2016, 10:57 AM
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Quote:
Originally Posted by mdcoa View Post
Resurrecting an old thread . . . well on the way to doing this injector pump seal replacement, but mine's got a lot of surface corrosion on the head, and the fuel cutoff solenoid body is resisting efforts at removal.

Two questions:
1) The solenoid comes with pre-rounded corners, and it feels like my 24mm wrench is just going to finish the job. It's currently doused in PB Blaster, and I'll try again tonight. Any thoughts on how to get it off if the wrench does indeed fail me? Obviously vice grips or channel locks--anything else I might want to try? I'm going to order a new solenoid today, so I'm not too worried about damaging this one.

2) If push comes to shove, can I replace the o-ring without removing the solenoid? i.e. does the solenoid prevent the rearward movement of the head, or is it just another obstacle to overcome as you stretch the o-ring around the head?

Thanks in advance!
15/16 6pt tapped into place may help
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  #16  
Old April 27th, 2016, 11:25 AM
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I can get a new pump for about $450 delivered so it's almost not worth fooling with a clunky old pump.
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  #17  
Old April 27th, 2016, 11:28 AM
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Originally Posted by o2batsea View Post
I can get a new pump for about $450 delivered so it's almost not worth fooling with a clunky old pump.
Whoa! Where are you finding that at?
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  #18  
Old April 27th, 2016, 11:36 AM
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Originally Posted by o2batsea View Post
I can get a new pump for about $450 delivered so it's almost not worth fooling with a clunky old pump.
That is cheap. But the fix described here is only $10 while being very simple to do with the pump on the engine. It is less work than removing the pump to change it for a replacement.
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  #19  
Old April 27th, 2016, 12:40 PM
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Yup, it's not that hard, although it'd be a good bit easier if the head on mine weren't so insanely corroded (just getting the timing inspection plug off the back was an event). . .

Good to know replacements are that cheap--I had no idea. I second the inquiry, Bill--where'd you find them for under $500?

But, provided this works, it'll be $10 and a few hours, and I'll be smarter about how stuff works.

Will try the 15/16" wrench--thanks for that tip.

-bill
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  #20  
Old April 27th, 2016, 12:54 PM
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Quote:
Originally Posted by mdcoa View Post
Yup, it's not that hard, although it'd be a good bit easier if the head on mine weren't so insanely corroded (just getting the timing inspection plug off the back was an event). . .

Good to know replacements are that cheap--I had no idea. I second the inquiry, Bill--where'd you find them for under $500?

But, provided this works, it'll be $10 and a few hours, and I'll be smarter about how stuff works.

Will try the 15/16" wrench--thanks for that tip.

-bill
Bill:

If the 15/16 doesn't work, I have a set of "Metrich" wrenches here that are designed to also work on rounded bolt heads without rounding them any further.
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