How to replace the fuel temperature sensor and injection pump cover seal replacement on VW Audi TDI

looks simple enough and I'm going to replace the triangle head bolt with a star drive or hex (whatever I can find at work that will do the job) :lol:

Any other seals that can be changed diy on the pump? Mines leaking like a goodun. Looks to be from the middle rather than the top (ouch on the wallet) but hard to tell in situ. Definately top rather than bottom of the pump.

Spill pipe and other connections seem tight so suspect a seal. However in the bosch seal 'pack' i dont know how many of these are diy and how many need expert hands. I know the shaft seals are a no no.
 
Any other seals that can be changed diy on the pump? Mines leaking like a goodun. Looks to be from the middle rather than the top (ouch on the wallet) but hard to tell in situ. Definately top rather than bottom of the pump.

Spill pipe and other connections seem tight so suspect a seal. However in the bosch seal 'pack' i dont know how many of these are diy and how many need expert hands. I know the shaft seals are a no no.


Keep looking I'll take the phone out to take piccies as I'm working on Sat as my seal pack and manifold gaskets turned up at home yesterday ;-)
 
Any other seals that can be changed diy on the pump? Mines leaking like a goodun. Looks to be from the middle rather than the top (ouch on the wallet) but hard to tell in situ. Definately top rather than bottom of the pump.

Spill pipe and other connections seem tight so suspect a seal. However in the bosch seal 'pack' i dont know how many of these are diy and how many need expert hands. I know the shaft seals are a no no.

Yep the passenger side oval one there is a spring and shim in there so be Carefull, also disconnect battery good chance of shorting the alternator I can give you the part no if needed for gaskek wipe pump with rag and if its leaking your see it dripping, but there is also one on the opposite side that needs pump removal to access it and it can fool you in to believing its the passenger side as it drips in the same path making you think it's passenger side if that makes sence .
 
Ok

so today I've been out and replaced the seals inside the FIP much easier that I expected - just awkward due to the fact you have to strip so much down to get to it!

anyway - I have just popped inside to warm up and grab a coffee, but before I go out and try to start it, I may as well change the fuel filter while I'm getting dirty.

So question is is the system self bleeding or am I looking at cracking the injectors while I crank it over??
 
Ok

so today I've been out and replaced the seals inside the FIP much easier that I expected - just awkward due to the fact you have to strip so much down to get to it!

anyway - I have just popped inside to warm up and grab a coffee, but before I go out and try to start it, I may as well change the fuel filter while I'm getting dirty.

So question is is the system self bleeding or am I looking at cracking the injectors while I crank it over??

Open all the injectors crank and close them as they get fuel. Engine may start as you go. So be aware.
 
You should be fine with just filling up the filter with clean diesel. It should start within 30 seconds.

Regarding the FIP seals you just replaced - I take it you don't deem their failure in any way related to the combination of vegetable oil and nitrile rubber you so vehemently denied on the other thread?
 
You should be fine with just filling up the filter with clean diesel. It should start within 30 seconds.

Regarding the FIP seals you just replaced - I take it you don't deem their failure in any way related to the combination of vegetable oil and nitrile rubber you so vehemently denied on the other thread?

Nope not at all

nothing was perished as I shall show when I post pictures later - it was leaking from the day I bought it - it's just increased to an unacceptable level over that last few days.

and if it's down to Veg oil - how come Aerofabrique is in the same situation? along with thousands of Americans? quick google search will show loads of people having similar problems
 
ManifoldStripped.jpg

manifold off for access - and inlets blocked with old gloves, last thing you want is to spend an hour hunting a dropped nut out of there!!

EGR Valve ewww!!
EGR.jpg


After a good soaking
EGRCleaned.jpg


anyway back to job in hand FIP pump
FIPtopGasket.jpg

Top seal - nice and easy - just fell out!

FIPLowerGasket.jpg

Second layer - I didn't mark off before I removed, but not essential as you'll need to adjust anyway

Inside the pump
FIPinside.jpg


LowerGasket.jpg

Can see here where the seal is pushed out, swollen and feels very brittle
 
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When putting all back together ensure the part circled in green
LowerGasketGreen.jpg


sits inside the cup circled in red
FIPinsidered.jpg


I missed on the first attempt - but practice a few times so you know you are getting it.

then loosely assemble everything and push the middle section as close to back of the engine as poss

then crank engine and slide left until the engine kicks into life and play around with the plate until you have a normal tick over - tighten everything down
 

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