Leaking 200Tdi fuel pump - Defender Source
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  #1  
Old May 23rd, 2014, 06:34 PM
javelinadave
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Leaking 200Tdi fuel pump

I swapped out my back axle this morning so now I have disc brakes all around. I took it for a test drive and all was well till I noticed a leak from the engine compartment. Long story short there is fuel leaking from the back of the fuel pump. From what I read it is the o ring in the picture below. I'm looking for some wisdom from somebody who has experienced this same problem.
Thanks,
Dave
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  #2  
Old May 23rd, 2014, 06:44 PM
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If rebuilding your existing pump becomes a last resort you can send it to Blue Ridge Diesel in Salem, VA.

Any rubber gasket supply can remove your old O-ring and measure it, then provide a new replacement. I would select viton over the standard neoprene (buna).

Good luck getting everything repositioned and put back together properly.
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Old May 23rd, 2014, 06:50 PM
javelinadave
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I just found this.
Anybody ever try this method?
Anybody know what sized o ring it uses?
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  #4  
Old May 23rd, 2014, 10:23 PM
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I had the same leak on my 300 Tdi. There are procedures and parts on dieselgeek.com. Search for a thread started by me with the title "300 Tdi & dieselgeek.com", which gives a few helpful hints for the 300 Tdi which should also apply to the 200 Tdi. The instructions link no longer works, but the writeup is still on their web site if you poke around a bit. If you have some questions or problems I can try to help but it's been a while. The most difficult part was removing the fuel shutoff solenoid, as it was siezed up pretty good.
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Old May 30th, 2014, 06:22 PM
javelinadave
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Well, with the online guide from www.dieselgeek.com, their o ring and a metric ton of courage I successfully swapped out the o ring. I don't have anything to add but go slow and read up before you tear into this project.
This web posting gave me the confidence to try this:
How to load up the springs in the pump.
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Old June 18th, 2014, 06:33 PM
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So it's leaking again after about 20 miles of driving. Anybody have any other suggestion before I pull the pump and hemorrhage money with a rebuild?
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Old June 25th, 2014, 02:21 PM
javelinadave
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Fixed the leak.....l I hope.
The bolt on the center back in the middle of all the injector piping was misting fuel everywhere. I wrapped it with Teflon tape and it's now dry.
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Old June 25th, 2014, 04:08 PM
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Quote:
Originally Posted by javelinadave View Post
Fixed the leak.....l I hope.
The bolt on the center back in the middle of all the injector piping was misting fuel everywhere. I wrapped it with Teflon tape and it's now dry.
That is the access port where you insert the micrometer to set the pump timing.

Glad it was a simple fix.
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