Hi all,

Have Disco 1 1995 TDI 300, not worth much these days so a leaky injector pump seemed an unecessary expense.

Using "dieselgeek.com" head "o" ring replacement procedure and
ebay seal kit from "protech_2008 (286)" KIT # ZZRGK223/1.

Procedure is pretty similar to Diesel Geeks info, just fired it up with no leaks, took me about 6 hours, could probably do it in 4 hours now.

Have to remove Fuel Lift Pump, injector lines, and fuel hoses so acces is good as the process is fiddly. Bleeding a cinch.

4 X 6mm 50 mm long hex high tensile bolts
2 X 6mm 45 mm long hex HT (for replacement if required)
T30 torx socket, preferably 1/4 inch drive.

5mm Hex (allen socket) again best in 1/4 inch drive.

The kit is about $45 AUD plus freight, I have measured up "O" ring and can say an alternate MS type "O" ring in the -140 size (2.237 inch) Inside Diameter , 0.1 inch thick or similar would be suffice.

The kit supplied is a "viton" type "o" ring, which stretches better over head assy. eg its better than the bosch original "o" ring.


will supply photos and step by step later.

now if I only could improve my brakes.................

regards
OZ

 

Teflon lined stainless braided flex lines with D90 front cailpers, pads & rotors.

 

Thanks AC,

Just fitted new brake hoses to front made in shop locally, have new discs on front, new fluid etc.

Mine is non ABS, so what I want to see is wheels lock up and skid on sealed road, otherwise just doesnt seem to brake well enough for my liking.

Can anyone else confirm wheels will ockup when brakes hit hard.
Pedal fells really firm and hard now, just not seeminly effective enough.

regards

OZ

 

Few tips for pump body o-ring cx:

1. For discovery bolts holding body some are torx 30 and others 5 mm allen.

2.Fitted dial gauge with an old sun visor rod to ensure pump is on stroke, eg spring inside at max compression (opposite of normal timing)

3. ONly bring pump body back enough to change o ring, eg no more than 1/4 inch,
also use vaseline or similar lubricant before pushing body back together

4. Bracket on engine side only has a very small clearance to slide o ring past,
i managed to do this but would suggest removing inner bracket from pump

and now......

I have to reseal pump front seal, which I will do in situ of course

regards
OZ