Former VWDieselParts.com Forum

Lets be more specific. The TDC mark on the flywheel is lined up with the mark on the housing, the mark on the pump is lined up with the mark on the mount, but the IP sprocket mark is off by 1/16 of an inch with the mark on the pump housing. If all that is correct, then you should be OK. The pump has...

Thanks, folks, for the tips. I will try yet again in a few days. Hjalber, I had seen your post but not the last few entries. The pictures are worth a thousand words! Nice job. I'm also going to see if I can find a wheel position where a couple of bolts thru opposite lug nut holes will hit the backin...

On my dipstick the handle is the only yellow part, and it is external to the engine. Coolant on the handle of the dipstick doesn't necessarily indicate a head gasket problem. I'd look for a coolant leak. Does the "yellow part" extend into the engine on your dipstick? Sound like you're well...

My Dasher project is progressing nicely. The engine is now in tiptop shape, thanks to you folks on the forum. New hoses, belts, glow plugs, oil & filters, antifreeze, and I've rebuilt the injectors and IP. It now starts immediately and no leaks. Thanks to all for the help so far. My latest probl...

There's an O-ring between the thermostat housing and the pump. You might check that first.

Could also be a hose leak. Often when I assume that a problem is caused by something I recently worked on, I find it's something else entirely. Worth a close look.

Tony B
81 Dasher 1.6na

The rubber covered seal is NAPA nos6614. The seal with the bare metal OD is NAPA nos6610. The OD of both seals is 1.108", the ID is .669" and the thickness is .276". My understanding is that either should work, but I would think that the rubber covered 6614 might give a better seal ar...

The Bosch seal kit does not include the front shaft seal. It must be purchased separately. The same seal is used on all VW mechanical pumps for the 1.6 and 1.9 engines from 79 to 96.

TonyB
Jacksonville, FL
81 Dasher 1.6na

Just did some research and it turns out that NAPA carries the correct seal for the 1.6 engine ip. It is an SKF part and the NAPA stock number is nos6610.

TonyB
Jacksonville, FL
81 Dasher 1.6na

I've recently resealed two injection pumps and both have the same problem - shaft leakage through the new seals. The first one leaked right away. The second one developed a leak after several minutes of cranking. No other leaks. There is no radial play in either shaft so the bearings aren't worn. As...

One other thing that will prevent it from starting is the ignition switch. I had a bad switch that would energize the fuel solenoid on the IP in the "run" position but not in the "start" position. If I could get it started, it would run fine. Check the voltage to the fuel solenoi...

just saw this on ebay this morning. Price is right!

http://cgi.ebay.com/ebaymotors/VW-Bosch ... ccessories

TonyB
81 Dasher 1.6na

Sounds like the timing is off. There are two places you can go wrong when you lock the pump & cam.
1. Make sure both lobes for #1 cylinder on the cam are pointing up.
2. Make sure the mark on the back of the pump pulley is up.

TonyB
81Dasher 1.6na

I recently completed a complete teardown & reseal. Yes, you will have some leftover parts. As I disassembled the pump, and removed each seal, I chose the correct seal from the new kit and labeled it. That worked out well. All seals except for the shaft seal were included. The shaft seal does hav...

Quantum-man, I don't much care for corn flakes. Would a Rice Krispies box work in this application??

Tony B
Jacksonville, FL
81 Dasher 1.6na