Replacement of housing-seal of Bosch VE Dieselpump

[bigjim]

Currently working on my Xantia 1.9TD (1997- 500.000 KM) dieselpump.
It leaks in winter, therefor I want to replace the seal in between the upper aluminium body, containing the gashandle axle and the pump housing.
I got stuck now due to a cover over the solenoid. I do NOT need to get to this solenoid, but this anti-theft cover now does not allow me to remove 2 of the 4 screws that holds the top part of the aluminium housing.
Does anyone have experience to do this while the pump is in the car? Can I grind of the edges only of the cover with a Dremel.
Any tricks of the trade are most welcome!

The anti-theft cover is visible on the right hand side of the pump (taken before I commenced):


Anti-theft cover as seen from the outlet-side of the pump (One screw removed, one rivet-screw visible, other is below outside of this picture):

[KennyW]

Welcome to the forum Bigjim,

I used a dremel with a diamond cutting blade to put a notch in the head of the screw and turned same with a screwdriver.

Also have had to used a persuader (small chisel and hammer) and gentle tap it to move then screwdriver.

I have thread from 4 years ago about my struggles with the pump, citrojim is the authority on all things fuel pumps. He has a thread about same as well worth a read.

Kenny

[taffy]

yea i remeber getting that of one of my old cars...took me (-expletive removed-) ages!! and all because one of those wires going into it had snapped!

[bigjim]

Welcome to the forum Bigjim,

I used a dremel with a diamond cutting blade to put a notch in the head of the screw and turned same with a screwdriver.

Also have had to used a persuader (small chisel and hammer) and gentle tap it to move then screwdriver.

I have thread from 4 years ago about my struggles with the pump, citrojim is the authority on all things fuel pumps. He has a thread about same as well worth a read.

Kenny

Thanks Kenny!
Yes, this worked thus was a good idea, used a circular blade as delivered with the Dremel. I was able to cut into two bolts. By hammering with a chisel they came loose and could be turned out easily.
After removing a hexagon (allen) bolt and a torx bolt at the back I could give the cover even more play. But it will not go out until the bracket plate is taken away. I released the nut at the bottom where it is connected to the engine. And also another (....) torx bolt. But it seems there are another two rivet-type bolts to be taken out.
Not there yet.

[Stewart(oily)]

Awful job! had to do one a few years ago after replacing an engine, why I had not thought of it while the thing was lying on the floor

[CitroJim]

Jim, I'm sorry, I'm a bit late to the party here... You have already received some excellent advice.

However, my rebuild guide here may still be of some use.

One method I've used in the past is a hammer drill running backwards with a small masonry drill that's just bigger than pilot holes drilled in the bolt heads. It works like an impact gun...

[KennyW]

Jim,

The cover plate is held on by the bolts but also a small pin which is the pain to remove.
I'll find my photos and post them up.

Kenny

[KennyW]

Jim,



and



and the pin



Pump 4 shows where pin is place in armour, please note pump removed for clarity

[bigjim]

I finalised the replacement of the seals, bush and o-ring. I did spend lots of hours. Mainly due to the badly accible little bolts and also the armoured cover. I worked with a grinder in the car, with lots of sparks, I hate that. Later used the Dremel as stated to make a groove for a normal flat big screw-driver.
There were 5 of these ant-theft bolts.
Anyway, I took some pictures so if anyone is interested please let me know.
So after assembly of the pump, and being my first work on a diesel-pump, I was very nervous if the engine would ever run again. Well it did and I took the Xantia for a test-drive.
After a 10 Km drive I parked the car in front of my garage and inspected the engine-compartment with the engine running. I noticed that there were drops falling from the bottom of the diesel-pump onto the lowerpart of the engine block. So... my work seem to be in vane. Although a doctor would say I have just excluded one possibility of the leak.
I am quite convinced that the leak is not in the upper aluminium cover. The seal has been replaced and everything is dry. About 1 drop of Diesel is produced (leaked) per 30 seconds with a stationary engine.
Since I cannot manouvre my head under the diesel-pump it is difficult to see where it might be coming from. My camera can get lower so I let it take a picture.
Here is one with a diesel-drop just about to fall...


I am interested in a suggestion were this comes from. I can imagine the sensor on the right, is not sealed right (what does this sensor do by the way?). Or the distribution end head has a faulty seal. Or there might be a seal at the back.

[bigjim]

I finalised the replacement of the seals, bush and o-ring of my Xantia 1.9 TD. I did spend lots of hours. Mainly due to the badly accessible little bolts and also the armoured cover. I worked with a grinder in the car, with lots of sparks, I hate that. Later used the Dremel as stated to make a groove for a normal flat big screw-driver.
There were 5 of these ant-theft bolts.
Anyway, I took some pictures so if anyone is interested please let me know.

So, after assembly of the pump, and being my first work on a diesel-pump, I was very nervous if the engine would ever run again. Well it did and I took the Xantia for a test-drive.
After a 10 Km drive I parked the car in front of my garage and inspected the engine-compartment with the engine running. I noticed that there were drops falling from the bottom of the diesel-pump onto the lowerpart of the engine block. So... my work seem to be in vane. Although a doctor would say I have just excluded one possibility of the leak.
I am quite convinced that the leak is not in the upper aluminium cover. The seal has been replaced and everything is dry. About 1 drop of Diesel is produced (leaked) per 30 seconds with a stationary engine.
Since I cannot manouvre my head under the diesel-pump it is difficult to see where it might be coming from. My camera can get lower so I let it take a picture.
Here is one with a diesel-drop just about to fall...




I am interested in a suggestion were this comes from. I can imagine the sensor on the right, is not sealed right (what does this sensor do by the way?). Or the distribution end head has a faulty seal. Or there might be a seal at the back. Can anyone give an opinion on what this could be, or proably is.

[CitroJim]

Jim, that sensor is not a sensor but the timing actuator. It's basically an electronically controlled injector that feeds diesel to the timing device piston to control its movement hydraulically. It's sealed with a big O ring.

So what seals exactly did you replace?

[Xaccers]

Those are the control wires for the timing electrovalve which is under the cap in the center of the photo.
It moves back and forth inside making small adjustments to the timing depending on signals from the lift sensor on No3 injector and the TDC sensor behind the gearbox.


Edit: The merge threads tool has been getting a lot of exercise recently.

[KennyW]

BigJim,

Could it be the seal at the distributor head leaking very slightly as this could have been disturbed when you were removing the body armour

I'm sure Citrojim will confirm same.

Here's a photo of head removed from body of pump.



Kenny

[bigjim]

Thanks all for your input in this. (Xac, Jim, Kenny)
I have replaced the housing seal (the almost rectangular one), the bush of the accelerator lever and the O-Ring of the axle of the accelerator. This because I noticed diesel on top of the vertical flat part where the type-number is punched/engraved into, and on most of the forums people were pointing to this. I think now remains three possible/plausible causes. The 1) O-ring on the side under a cover, 2) the O-ring around the distributor head, 3) the O-ring at the Timing Actuator (as you guys pointed out to me) 4) The O-Ring at the back under a cover.
Since I would like to leave the pump in the car if possible, I really would like to replace the faulty part, due to accessibility.

Question; So, does anyone of you know a more scientific approach to get to the right conclusion to which seal it is?
I am thinking no to clean with a lot of tissue. Bind a tissue arround the bottom and taking it off after a minute. The source should be indicated by the wet spot. Not sure if this would work.

If I look to the picture I would reckon that this process has been going on for a while, the build up of dirt is larger at the end of the pump. That would point to the Timing Actuator or the Distributor. I suppose these two can be replaced in situ. There is a video on youtube of an american guy taking the distributor-head off by sliding it out slightly.

[KennyW]

Jim,

Check the distributor head for any loose nuts and tighten any which are loose. This may cure your problem.

It is possible to remove the head but there are springs at the back which could fall down causing grief.

Kenny