Correct injection pump cover gasket from Bosch kit?

[Nevadan]

Which is the correct gasket to use for the injection pump cover from the Bosch rebuild kit?

There's two gaskets that would appear to work: a fatter one with nipples on it that's moulded to the shape of the groove in the cover and thinner one that's not molded, it's basically a circle.

I tried the moulded one first but the cover would not compress the gasket onto the pump. I then put the thin one on and put everything back together but it appears to be leaking.

Is the thinner gasket for some other pump? Is the thicker one for some other pump?

I just completed the LDA leaking o-ring replacement from Andrew's writeup here viewtopic.php?f=8&t=9372&start=15 and that went well but now need to know what to do so I can use my '85 TD Jetta again tomorrow.

While doing the LDA o-ring I found another step to add to Andrew's writeup. I've got picture's that I'll post tomorrow that show what happens when the nut under the "star wheel" adjuster is loose. The LDA pin has to go through a hole in the threaded pipe that screws down into the LDA and if the lock nut is loose that pipe will turn and not allow the pin to project into the tube and thus make contact with the tapered LDA shaft. Pictures will make more sense.

[TylerDurden]

The suggested method is to carefully cut the nubs off the formed seal for the lid.

[Nevadan]

Thanks TD!

Most people underestimate the value of knowledge. I don't!!!!

[Fatmobile]

I use a razor blade to remove the nubs from the formed gasket.
Get all of them off, I have a picture around here showing the thin side busted out from the pressure once tightened,... I used to just use nippers and didn't remove enough.

[EcoTX]

I've never cut anything off a gasket and no pumps of mine are leaking.
I've found myself using the round one on MK1 pumps, and the molded fit one I use on the MK2 pumps.
They seem to work and seal just fine for their specific application.
I don't know where this cutting business came from, but I do not think BOSCH intended you to cut anything off their gasket kits to work right...but it seems some people do it and get away with it.

[Nevadan]

I've got the thin one in right now but don't trust it. I've cut the nubs off the new one and have it ready to put in.

It was VERY cold (around 15 degrees F) when I was attempting to put the moulded one in with nubs on and the pump cover wouldn't compress onto the pump body despite over-torquing the allen bolts. It was on my "practice" pump and I really put pressure on it. Perhaps if it was 100F it would have worked!