205 TD : dépose pompe d'injection

Hi Jeff,

Pleast to hear from you again :-)

Ok, here's the story... I'm still facing problems with my brother's '91 205 DTurbo, there's a fuel leak on the Diesel pump's driveshaft, this involving the fuel to leak on timing belt down to the floor. Not fun. Now I've removed the timing belt (it was a bit playing with my nerves :-( ), but the procedure to remove the Diesel pump isn't that easy : they say I have to remove the three front screws (the ones which are on the belts side) and the back screw, OK I can see them all, but the third screw, which is rather on the bottom-side seems impossible to reach with a wrench:-( Do I need a special tool ? Do I need to remove whole engine (I hope not) ? Another point, now the pump's driving gear is blocked, could I remove it (the 2 little bolts + the big bolt) without losing the pump's advance setup ?

TIA & Regards, G.T snipped-for-privacy@worldonline.fr

Hello,

Of course I typed with my fingers not on the good keys :-) Read "Pleased to hear from U again".

Regards, G.T snipped-for-privacy@worldonline.fr

or you can sometimes "just get onto it with a 13mm socket and wobbly type extension and ratchet once its loosened you can spin them off with your fingers for what its worth our diesel specialists here in the uk change the seal with the pump fitted after removing the pulley

Hello,

Thanks. Finally I managed to remove the whole pump mounting (it's just secured with 4 13mm bolts) using a 13mm wrench.

Regards, G.T snipped-for-privacy@worldonline.fr

I had trouble getting at the third bolt too. After trying (and failing) to get a spanner onto it for 20mins I took the alternator off and then it was easy to get at with a normal spanner.

Phil

Hello,

I didn't need to put the alternator out, as I finally took the whole pump mounting plus the pump out. The problem was to take the fourth bolt out (13mm too), because a hose was in way, and a a 13mm spanner was just too long (hitting the metallic timing "cover"), but I finally took it out with a little unbolting angle (due to the steel plate, which was agressive just where I needed to put my hand). Finally took all this out, and still have 5 fingers at my left hand :-) Now I've done it once, I guess the refitting will be a kind of joke, say 1 hour for pump & pipes... a lot more for timing belt :-/

Regards, G.T snipped-for-privacy@worldonline.fr

you dont have to remove timing belt when removing pump leave the pulley on the timing pins/bolts

Hi Jeff,

Sorry, I haven't seen your post...

I thought it was necessary. Well, we replaced the timing belt, of course - not the biggest part of the bill, servicing a Diesel pump costs a lot (it was around £400 exc. VAT, most was labour (~£300 exc. VAT). Ouch ! BTW, we kept the tensionner, as it was just some thousands kilometers old.

Regards, G.T snipped-for-privacy@worldonline.fr

Hello,

Works great, took its mot, my brother's called me today, still no problem.

True. Oh, you certainly know I'm a XU/XUD enthousiast :-)

No, I haven't heard of something concerning a high mileage 309D. I've heard of such a case concerning a Golf Diesel (which makes me think a 1,000,000 km Golf can't have its original gearbox). I guess a 1 million miles 309D is at least as possible as a 1,000,000km Golf. Damn, I guess I really hate VW :-)

Regards, G.T snipped-for-privacy@worldonline.fr

Hello Jeff,

BTW I can tell you why there was a fuel leak on pump's drive end : worn shaft seal. Not amazing for a leak, huh. But the seal destruction was caused by the use of a Bosch output screw on the Roto (Lucas) pump. You probably know the Bosch output screws have a really smaller hole for fuel return, compared to Rotos. This causing an overpressure, which finally blown the seal. C'mon, buy a used car :-( Really a stupid fail, IMO, but why would my brother (had a B-Tech 1st as an auto mechanic) have a look to the fuel return screw ?

Regards, G.T snipped-for-privacy@worldonline.fr