Strong Diesel Smell...

[marvins_dad]

...INSIDE!

Seems to go away when driving, but at stand still it really starts to smell inside the car.

I think there was a thread once before on this topic, but I couldn't find it in the search....if anyone can point me to it I would appreciate it, otherwise...any thoughts...anyone had this issue before?

I haven't lifted the hood and checked to see if there are any leaks yet...just thought if anyone had the same issue they might tell me where to look.

[DR.billZ]

Diesel fuel or diesel exhaust smell?
If it's exhaust make sure the rear hatch is FULLY latched.

If it's fuel then obviously there is a leak somewhere(yeah I know.....like you don't already know that)

[kcfoxie]

IIRC my friends 03 PD Golf had this issue and it was the access panel to the fuel sensor/fuel pump to the tank had a lose bolt or two and let the fumes come in. I'd start at the tank and make sure that the top seals are good.

Lucky for you the fuel isn't flame ignitable

[Growler]

Antoine, you need to take off your engine cover and see if your pump has started leaking, or if the inter-injector lines (braided black small ones) are leaking.

lets hope its the small black lines.. cuz if its your pump, you need to give runonbeer (rob) a call or PM from tdiclub to see about a new seal for your fuel pump.

good luck!

[cep]

Most of the time it is a split in one of the rubber return lines from the injectors.

[marvins_dad]

Spent some time under the hood in my work clothes when I got home...looks like the fuel is leaking from the injector pump...
Any ideas if this gasket can simply be replaced or is this a sign of a larger problem?

You can see from the picture a bubble in the fluid from the seal that must be broken....then a pool of fuel in the bolt below in the front as well as fuel soaking the block below.

[Dorado]

Yep, our injector pump leaked too. In some cases, the switch from LSD to ULSD since Oct 2006 has made injection pump seals leak. There are two seals to replace (top and middle), and dieselgeek is out of stock of the middle seal. Impex also sells the seals:

dieselgeek.com

worldimpex.com

[marvins_dad]

So it is possible to pull the pump and replace the seal?

I looked at my Bentley and only found them talking about parts that go on the injector pump and not how to take it apart.

Just don't want to destroy it or take on a project that should be handled by VW Techs.

[marvins_dad]

Okay, the official name is Injection Pump...the injector pumps are different.

[hannaco]

I do not know about the middle seal, but the top seal is easy to replace. Just lift the lid, and put in a new seal.

[lojasmo]

Originally Posted by marvins_dad

So it is possible to pull the pump and replace the seal?

I looked at my Bentley and only found them talking about parts that go on the injector pump and not how to take it apart.

Just don't want to destroy it or take on a project that should be handled by VW Techs.

Actually, IIRC, pump rebuilds are parted out to Bosch techs. I wouldn't do it MYself...and there isn't much I wouldn't do myself.

[marvins_dad]

I found a couple threads on the TDI forum that scare me, but inform me at the same time...

http://forums.tdiclub.com/showthread.php?t=115689

http://forums.tdiclub.com/showthread.php?t=75740

A How-To on a '98...not sure if this would be the same on my 2002 though...
http://anglo-hexon.net:88/tdi/ip_seals/

[whitedog]

Yep. It's the same. You must have VAG-COM to reset the IQ when done. You could also take a drive to Austin and see Robbie down there.

[marvins_dad]

Have the Vag Com...love Robby, but really don't feel like a trip right now. (he did my timing belt)

I am just having problems figuring out what is supposed to be marked so it lines up...the how-to talks about marking a few things before disassembly because it has to go back exactly...then fine tuned with the Vag...but I haven't seen documentation or photos on where those marks should be.

[marvins_dad]

So...

Lewisville VW - basically gave me the "come in and we will have a Tech look at it..." speal...like I want them spending $90 to tell me what I already know.

Lord of the Rings (because they do Audi and VW repairs) suggested I call a local dealership and talk to a specific person about it....see if it is under powertrain warranty...

MetroVW - levels with me and was real honest...since I have a 2002 the powertrain is only 60k (I have 72k) - they apparently changed the warranties on 2002 from 24k/90k? to 48k/60k...what a crock of crap! Like their product now isn't good until 90k...apparently not! They wouldn't repair the pump anyway, just replace at $1500+labor. Apparently there isn't a VW part for the seal...and they don't do repairs to the pumps themselves.

Back to Lord of the Rings...Bob, told me basically the same thing, the would work up a quote of replacing, but not working on the pump itself, because they suggest any work on the pump be done by a certified Bosch repair shop.

Called my local Bosch repair shop...apparently it would only cost about $175 parts and labor to replace the seal, but if they had to pull the pump it would cost 5 hours labor at $75/hr. Not sure why they would have to pull the pump (even if they did show it pulled in the how-to...but he didn't talk about doing that in the how-to)...that total would be $550.

So...here I sit...probably too late to get the parts for a Sunday attempt...wondering if I can repair it myself and possibly with a vw tech friend of mine or if I should bite the bullet and put it into the Bosch repair shop and hope they don't have to take it off the car.

[ChristopherC]

I was under the impression the ULSD/seal an issue limited to older models. Guess not. Is this issue across all model years or a specific pump generation/design then?

[kcfoxie]

Originally Posted by marvins_dad

So...

Lewisville VW - basically gave me the "come in and we will have a Tech look at it..." speal...like I want them spending $90 to tell me what I already know.

Lord of the Rings (because they do Audi and VW repairs) suggested I call a local dealership and talk to a specific person about it....see if it is under powertrain warranty...

MetroVW - levels with me and was real honest...since I have a 2002 the powertrain is only 60k (I have 72k) - they apparently changed the warranties on 2002 from 24k/90k? to 48k/60k...what a crock of crap! Like their product now isn't good until 90k...apparently not! They wouldn't repair the pump anyway, just replace at $1500+labor. Apparently there isn't a VW part for the seal...and they don't do repairs to the pumps themselves.

Back to Lord of the Rings...Bob, told me basically the same thing, the would work up a quote of replacing, but not working on the pump itself, because they suggest any work on the pump be done by a certified Bosch repair shop.

Called my local Bosch repair shop...apparently it would only cost about $175 parts and labor to replace the seal, but if they had to pull the pump it would cost 5 hours labor at $75/hr. Not sure why they would have to pull the pump (even if they did show it pulled in the how-to...but he didn't talk about doing that in the how-to)...that total would be $550.

So...here I sit...probably too late to get the parts for a Sunday attempt...wondering if I can repair it myself and possibly with a vw tech friend of mine or if I should bite the bullet and put it into the Bosch repair shop and hope they don't have to take it off the car.

Crap, that's a just sucky. Would I be a total tool if I suggest taking the pump out yourself (you've got the bentley) and clamping your lines off then taking the part itself to the Bosch place and paying the mere $175 to rebuild it, then reinstall and reset with your VAGCOM?

[marvins_dad]

Well...crossing fingers - I ordered the seal kit from World Impex and the tool from MetalNerd just now and if all goes well I will start on Sunday...hopefully finish on Sunday too.

I'm also hoping to keep the unit in the car during the repair, can't think of why you would completely remove (except to take it to the Bosch place like you mentioned KC).

Got alot of reading to do and need to resusitate my VagCom from my hard drive crash this weekend (when it rains it pours LOL)

[kcfoxie]

Good luck, if you think of it take some photos for others.... i bet this will become one of those 'known' problems like the MkI Rabbits and blowing Headgaskets, or the alarms on the MkIIIs, or the door sensors in the MkIVs (and nortoriously the beetle).

[cep]

Originally Posted by ChristopherC

I was under the impression the ULSD/seal an issue limited to older models. Guess not. Is this issue across all model years or a specific pump generation/design then?

Well, it certainly goes away with the PD engine but I would not be too quick to attribute this to ULSD.