brandon Posted May 25, 2015 Report Share Posted May 25, 2015 Hi Everyone, looking for help on our 84' 504 STI Turbo Diesel: Car runs very well but recently we noticed fuel leaking... then today it was practically pouring out of the injection pump, maybe near the back close to where the 4 line fittings are located. Car is still running perfectly. What do we do? I have read about rebuilds? Car only has 70k miles on it so maybe it needs a new seal or gasket? Is this something I should try to tackle? Any step-by-steps on this? Many thanks for any help. Quote Link to comment Share on other sites More sharing options...
Bean Posted May 25, 2015 Report Share Posted May 25, 2015 Hi Brandon, There's lots of info online on Bosch VE injection pumps, and I did post contact info for a guy in Canada that reseals them on the side, just not sure he still does since he moved. Lots of other places can do it for the same $4-500 range if you look around and deal direct with diesel injection specialists rather than general repair shops. Removing and installing will be DIY, but resealing is pretty advanced. I wanted custom stuff done to mine as well, so lacking experience in advanced pump tuning/modifications, I had the work done in addition to resealing. Rabin Quote Link to comment Share on other sites More sharing options...
brandon Posted May 25, 2015 Author Report Share Posted May 25, 2015 Thanks Rabin, I contacted the folks at Performance Diesel about a quote for the re-seal. I have also found one already rebuilt on eBay: what do I check to make sure it will fit my car exactly? Here is the pump link: http://m.ebay.com/itm/121573198467?nav=SEARCH Quote Link to comment Share on other sites More sharing options...
brandon Posted May 25, 2015 Author Report Share Posted May 25, 2015 Also the email j_holubek (at) live.ca was returned to me undeliverable. Any other contact info for Jeremy that re-seals these pumps? Quote Link to comment Share on other sites More sharing options...
Bean Posted May 25, 2015 Report Share Posted May 25, 2015 Sorry - I haven't heard from Jeremy in a while. The pictures of the ebay IP doesn't have the gear drive on the front so not sure if it's missing or if it's a VW pump... If you have the means, spending $1200ish on a Giles rebuild / tune for performance will transform the car into a much more modern car with very useable gains. Once my TD's are plated and functional I'll definitely send an IP to Giles for a custom tune as I want to maximize performance. If not - where are you? Joe found a place in Raleigh NC that resealed his pump for $400 IIRC. Rabin Quote Link to comment Share on other sites More sharing options...
brandon Posted May 25, 2015 Author Report Share Posted May 25, 2015 1200 is definitely out of my budget, sadly. I live in Pittsburgh, PA . I could ship to NC. Trying to have this back on the road ASAP as it is a daily driver for us. Quote Link to comment Share on other sites More sharing options...
tulaweb Posted May 28, 2015 Report Share Posted May 28, 2015 I think Joe had two of them done at that place local to him in NC. I was talking to Steffen Moller at the Carlisle show a couple of weeks ago about my leaky pump. He says that when it's that typical leak on the back of the pump near the block it is usualy one O ring on a surface plate back there which deteriorates from the heat of being right next to the engine block. Unlike resealing the whole pump, replacing that one O ring is a very reasonable self service job. It does of course involve removing the pump but you'd have to do that anyway to send it off for a reseal. I haven't investigated further but I think maybe it's this. Quote Link to comment Share on other sites More sharing options...
brandon Posted June 2, 2015 Author Report Share Posted June 2, 2015 Thanks Tulaweb. My pump is actually leaking from the block where the injector lines connect (square-ish looking seal). I have located a replacement pump but it is from an later model. Everything seems identical except for the timing advance solenoid on the late model one. Any ideas on how to either bypass the solenoid or wire it into my 84'? Maybe wire it into some sort of temp sensor? Quote Link to comment Share on other sites More sharing options...
tulaweb Posted June 4, 2015 Report Share Posted June 4, 2015 I've seen a kit for replacing that seal as well. I think I recall that it includes a shoulder bolt of some kind so you replace one of the bolts that holds that part on and the special bolt then limits the travel when you have removed the other bolts so you can open it enough but not far enough for internal parts to fall out of position. You are then able to remove the original seal and stretch the included viton seal over the end and into place. I think you can even do that with the pump in place. You just have to disconnect the injector lines. I think the kit also includes plastic caps to cap them off while you work. I haven't done this myself, but I'll see if I can find where I've seen the kit, and the very detailed illustrated instructions. Quote Link to comment Share on other sites More sharing options...
brandon Posted June 4, 2015 Author Report Share Posted June 4, 2015 Thanks Again Tulawab! This sounds ideal! Quote Link to comment Share on other sites More sharing options...
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