A

Avocet1

Well-Known Member
Saw my old FL1 earlier in the week (now being left to live out the remainder of its days with my dad). Unfortunately, there was a small patch of diesel under it. The car was parked at a sideways angle, so it was the front, right hand (as you look at the front of the car) corner. I suspect, it might have come from elsewhere and run along the undertray though.

Car starts and runs fine. He hadn't noticed anything amiss. Looking on here, the high pressure diesel pump seems to be a common problem. Do they ever leak without giving starting or running trouble though? Also, I can find seal kits for the pressure regulator, but other sites show different kits:

https://www.ebay.co.uk/itm/25497869...qXT2NszF11uF3jyhsRJaGEmQB-j7szqlX-tzgpBnbAr48

and

https://www.ebay.co.uk/itm/161857157840?hash=item25af703ad0:g:MHMAAOSwuTxV8zh8

Is it worth doing both while the pump is out? Is it worth buying genuine Bosch, or do the cheap eBay no-name seals work fine?

Thanks in advance.
 
Good to see you :D

Dunno about those seals/kits - but if car is in use, be careful for fuel leaking from the pump into the sump. Be worth checking the level and making sure it hasn't gone up.
 
GrumpyGel said:
Good to see you :D

Dunno about those seals/kits - but if car is in use, be careful for fuel leaking from the pump into the sump. Be worth checking the level and making sure it hasn't gone up.
Click to expand...
Thanks! It's interesting you should mention that. The oil was a bit over the top mark, last time it was changed (my fault!) but I'll ask him to sniff the dipstick and see if it smells of diesel (or worse, has grown some more oil)!
 
Avocet1 said:
Looking on here, the high pressure diesel pump seems to be a common problem. Do they ever leak without giving starting or running trouble though?
Click to expand...

Yes, often they can run on for ages with just a small leak. I drove mine for about 3 months with a small diesel leak, it even passed the MOT as it wasn't too large.
In the end I replaced the pump, as I didn't like the idea of dripping money on the floor. :eek:

@kernowsvenski has had 2 pumps (I think it was 2) fail suddenly, leaking loads of fuel and stopping the engine. I've changed a failing pump for him too, but I can't remember why now.:oops:
It's just luck what failure mode you get.
 
Arctic2 said:
This is the kit you want for the regulator.
BMW 525d 2.5 Common Rail Pump Pressure Regulator seal kit Bosch x 1 | eBay

This kit for HPFP.
Bosch CP1 Mega Seal Kit – Ribble Valley Diesels Ltd

High Pressure Fuel Pump Seal Repair ORings Kit For Vauxhall Diesel Bosch CP1 UK | eBay

Your link rom Poland they want £9.48 postage :eek:
Click to expand...

Fantastic, thanks! I hadn't even spotted that the other one was from Poland!

The Ribble Diesels one looks to have an oval gasket in it, like the one in the pressure regulator kit. Does it include the pressure regulator stuff too?
 
Avocet1 said:
Fantastic, thanks! I hadn't even spotted that the other one was from Poland!

The Ribble Diesels one looks to have an oval gasket in it, like the one in the pressure regulator kit. Does it include the pressure regulator stuff too?
Click to expand...

It looks like it does. any of the above will do the job.
SI39oRhl.jpg
1

Rust can get between the joints so it leaks.
cO4fWmol.jpg
2

Get the regulator one with the three seals some only come with two seals always add the black large seal.
sJBFbU5l.jpg
3

o8etf29l.jpg
4

maLRovfl.jpg
5

Make sure you take it apart in a clean dry area.

Reminder you will need the special tool to remove the HPFP from the car, and a 17mm Allen key.
XcNjgeVl.jpg
6

jhBIbi4l.jpg
7

17mm nut off the injector pipes work good, which i had spare.
eIaigzul.jpg
8

eIaigzul.jpg
9

t1p0N1rl.jpg
10

lWAJHbXl.jpg
11

once the cap is out you can remove the nut off the pump.
Z6oWsTjl.jpg
12

vdshPzzl.jpg
13

The special tool can now be inserted.
AN0sn04l.jpg
14

oDQMnEJl.jpg
15

Now remove the nuts of the back of the HPFP.
BXUqxusl.jpg
16

And the fuel line.
Jj1AqzGl.jpg
17

lots of work to be done before you get to all the above, manifold removed, starter removed, etc

Special Tool.
Rover 75 BMW DIESEL High Pressure INJECTION PUMP PULLER SPROCKET REMOVAL TOOL 3696893325947 | eBay
 
Avocet1 said:
Saw my old FL1 earlier in the week (now being left to live out the remainder of its days with my dad). Unfortunately, there was a small patch of diesel under it. The car was parked at a sideways angle, so it was the front, right hand (as you look at the front of the car) corner. I suspect, it might have come from elsewhere and run along the undertray though.

Car starts and runs fine. He hadn't noticed anything amiss. Looking on here, the high pressure diesel pump seems to be a common problem. Do they ever leak without giving starting or running trouble though? Also, I can find seal kits for the pressure regulator, but other sites show different kits

Thanks in advance.
Click to expand...

Hi,

You need to be sure that leak comes from the pump before removing it ;) diesel can leak from anywhere else ... leak from the fuel return line, and fuel pipes under the erg valve are also a very common issue ...

The pump has 3 covers, it can leak from one cover.
If the pump is leaking from one cover, sometimes is sufficient to replace the seals, sometimes you need to replace one cover.

If there is only a small leak, you will not have any problem starting when warn, but you can have issue starting in winter. If the leak stop just after starting, you can run like that for months ...

If you put a new pump you will not have any issues for the 10 next years.
If you repair the pump, it better to replace all the seals, it takes less than removing the pump again ...
 
Last edited:
Nodge68 said:
Yes, often they can run on for ages with just a small leak. I drove mine for about 3 months with a small diesel leak, it even passed the MOT as it wasn't too large.
In the end I replaced the pump, as I didn't like the idea of dripping money on the floor. :eek:

@kernowsvenski has had 2 pumps (I think it was 2) fail suddenly, leaking loads of fuel and stopping the engine. I've changed a failing pump for him too, but I can't remember why now.:oops:
It's just luck what failure mode you get.
Click to expand...

The pump @Nodge68 fitted for me was to replace the THIRD failure I'd had in nine years. The first one went suddenly whilst I was driving but I had noticed a diesel smell a day or two before but didn't locate the leak. The second let go with no warning at all and left a large pool of diesel on a dual carriageway slip road, and the third started leaking between one of the outer plates and the pump body. I spotted it and sourced a replacement, but it didn't quite last long enough to get me to Nodge's place to fit the replacement. All three failures left me at the side of the road awaiting recovery.
 
kernowsvenski said:
I spotted it and sourced a replacement, but it didn't quite last long enough to get me to Nodge's place to fit the replacement. All three failures left me at the side of the road awaiting recovery.
Click to expand...

Ah yes I remember now, you arrived being towed behind a recovery vehicle. :eek:
 
kernowsvenski said:
Maybe, maybe not. My experience is...
  1. Original (assumed) pump replaced May 2016 at roughly 108k
  2. 2016 pump replaced June 2019 at 135k
  3. 2019 pump replaced February 2022 at 160k
Click to expand...
Apart from the original, were the others seconds hand ones, or had they been refurbished with the seals? also did you have or do you have a synergy on your FL1
 
Arctic2 said:
Apart from the original, were the others seconds hand ones, or had they been refurbished with the seals? also did you have or do you have a synergy on your FL1
Click to expand...
The first two pumps were supplied and fitted by garages. I don't know if they were new or remanufactured units, but the one Nodge fitted was a Lucas remanufactured one. I did have a synergy unit running for a few years but as time went on I got less and less happy with it. It may have contributed to the first couple of failures, but It was switched off for most of the life of the last pump to fail, and removed a while before it went.
 
What we found on the R40 club that 99% of the time a HPFP failed it had a synergy fitted, and advised to have it removed and have a remap instead, which bought it up to a 160.
 
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