Pulling IP this weekend
 

I am going to pull the IP this weekend. Sense the weather has turned cold it has now turned into a sieve.

I think the leak is coming from the bolt on the back, but i am going to replace as many seals as possible. i would like some pictures, tips and tricks to doing this. I have been doing allot of searching and found some stuff like using STP engine treatment on the o-rings, and pics on the fuel pin seals. and how would i go about changing the o-ring between the pump and the head. thanks.

I have a link to the rebuild instructions at home. When I get home today I'll post it. It has pictures and step by step instructions. I think it's for a 4 cylinder VW diesel but it's basically the same pump.

Are you talking about the return banjo?

This is going to be fun.

first remove the top of the pump with the fuel pin and all (mark and remove full power screw, and good time to put in a 3200 gsk)

2. lay pump on its side, remove the bolts from the pump head and carefuly remove it from the pump.

3. all the pins and springs you see will fall out ( its ok).

4. the o-ring is on the pump head .

5. take the two pins and all the shims and clean them and put them back together with a little ( very little) grease between them so that they stick together, then put grease in the holes that the pins and springs go in on the pump head and place them in it ( this makes them stay in place when you reinstall the head)

6. Then stand the pump on its nose ( gear shaft down using a short pice of 4" pipe 3-4" long as a stand)

7. there is a small disk with a hole in it under the rod that the two big springs sit on make sure it is under it and that it is clocked right on the of set pin that is used to time it.

8. there is a hole in the side of the ring on the large rod that has to line up with the lever on the inside wall of the pump #4738

9. Then place the pump head back on making sure to line up all the pins and springs

note the two small springs go on the part # 4738 the pins go inside the two large springs, the large shaft will go into the pump head.

10 reinstall the top of the pump and then replace the full power screw to the marked spot.

it is pretty clear how it goes together but if you have and ?? let me know

I plan to make a realy good guide with many more pics and ( Can only have so many on here at a time) better instructions soon and post it.

I also have more pics under 3200 spring help

no, the 3 sided bolt on the block side

1stgen545 are the parts "keyed" so they only go back one way and timed correctly

Yes it will only go one way. heres a pic also the bolt on the side of the pump close to the front with the small triangle shaped pice under it is the lock bolt for the pump. Remove the bolt and the small pice and then reinstall the bolt ( snug but not to tight) and it holds the pump in time.

Sweet i got my 3200 spring today[guitar] its smaller than i thought it was but it has 366 on the side.

do i need the special tool for the 3 sided bolt or can i use a socket?

I have no idea, didnt pull that part.

well i got the new seals and the 366 spring installed today, and just as i was finishing up with the hold down screw on top of the throttle shaft and snapped the shaft right at the bottom of the threads.[verymad]

Well now i need a new throttle shaft. i need a part number i can give the pump shop on monday, thanks.

See this "sticky" it has an exploded view of the pump with part numbers

https://www.dieseltruckresource.com/...15&postcount=9

OK thankyou

[quote="B" SCARED;1716801]Sweet i got my 3200 spring today[guitar] its smaller than i thought it was but it has 366 on the side.

do i need the special tool for the 3 sided bolt or can i use a socket?[/quote]

You can get the special tool [URL="http://www.emiata.com/DieselVW/3SidedSpecialTool.htm"]here[/URL] for under 10 bucks. It's required to pull the special bolts which hold the governor throttle lever assembly in place. DON'T overtighten them.

The complete gasket kit is $20-25 bucks but the front seal is extra if you get the Cummins kit so be sure you get the large one. The small one is for the VW's and such.

I have a VW IP seal job coming up so I'll take pics of it this time.

Edwin