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 Post subject: Injection Pump Seal Kit: DGK-126
PostPosted: Tue Jan 31, 2012 12:50 pm 
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Turbo Charger

Joined: Tue Dec 22, 2009 1:01 pm
Posts: 985
Location: Michigami, USA
Here's what you get:

A box:
Image
A bag inside:
Image

Little bits in the smaller bag:
Image
Sizes are approx. OD, section (on o-rings). Coin and ruler are for visual scale, not in kit.

Full rez image of bits:
https://picasaweb.google.com/lh/photo/q ... directlink

Edit: added alphabetical labels to image, and a table below so parts can be identified.

Label = Part# - Description - [Location # on Bosch diagram] (below)

A = 1461015300/1460206303 - cover gasket - [92]
B = 1460056302 - "Buffers" (Bumpers?) - [15]
C = 1462010300 - Orings for cold-start covers - [30,36]
D = 1900210154 - Oring for hi-pressure head - [51]
E = 1900210131 - Oring for hi-pressure end-chamber (official name?) [129]
F = 1410407004 - cardboard sleeve for out-bolt?
G
H
I
J = 1420210047 -Governor shaft* [109]
K = 1900508009 - caps for delivery valves [140]
L = 1460210301 - larger o-ring for Cold-start shaft w/bearing & high idle - [39/3] (poss fits top o-ring for pressure regulator [134])
M
N
O = 1420210047 -Governor shaft* [109]
P = 1460210008 smaller - o-rings for Cold-start shaft and Accellerator shaft (fit into groove on shaft) [39/3] [66]
Q = 1460210319 - Full-load screw (max fuel) [91]
R
S
T = xxxxxxxxx? - copper washers for banjo fittings: In, Out.

* "J" and "O" have both been used successfully


If you have updated part info, please post and it will be added to the table.

Edit: updated cold-start info 1/8/2013



Image


You might also want the input shaft seal: 1 460 283 312
Image
(Do not let a person in a suit use this seal.)

_________________
Have a nice day.


'82 Westy 1.9 N/A - 23.5mpg
'86 Jetta TD - 45-50mpg
'89 Jetta N/A - 51mpg
'81 Dasher Wagon 1.6 N/A - 52mpg
'91 Jetta ECOdiesel TD - motor donor, clean shell & tranny for sale
'84 Wasserboxer - DOA, parts donor

'82 Caddy 1.6 N/A - Sold


Last edited by TylerDurden on Wed Jan 09, 2013 6:00 pm, edited 3 times in total.

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 Post subject: Re: Injection Pump Seal Kit: DGK-126
PostPosted: Wed Feb 01, 2012 11:29 am 
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Global Moderator

Joined: Wed Oct 30, 2002 10:28 pm
Posts: 6904
Location: north central Iowa
Great pics.
Looks like I was supposed to take off my suit put on a hard hat and dress like a plumber to install this.
Ooopps.
Now we just have to list which ones go where.

_________________
'91 Golf gasser converted to turbo diesel.
'83 Rabbit gasser, converted to diesel, then converted to run on vegetable oil.
2, '84 GTI projects cars


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 Post subject: Re: Injection Pump Seal Kit: DGK-126
PostPosted: Wed Feb 01, 2012 11:45 am 
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Turbo Charger

Joined: Tue Dec 22, 2009 1:01 pm
Posts: 985
Location: Michigami, USA
The box indicates an illustration should be included, but there was none in the box I bought. I'm going back to the supplier today, to see if they have one.

_________________
Have a nice day.


'82 Westy 1.9 N/A - 23.5mpg
'86 Jetta TD - 45-50mpg
'89 Jetta N/A - 51mpg
'81 Dasher Wagon 1.6 N/A - 52mpg
'91 Jetta ECOdiesel TD - motor donor, clean shell & tranny for sale
'84 Wasserboxer - DOA, parts donor

'82 Caddy 1.6 N/A - Sold


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 Post subject: Re: Injection Pump Seal Kit: DGK-126
PostPosted: Wed Feb 01, 2012 1:25 pm 
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Turbo Charger

Joined: Fri Jun 24, 2011 10:50 am
Posts: 451
Location: erie,pa and akron,oh
this makes the thought of doing this job somewhat easier and harder all at the sametime.

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91 jetta gl na german built
91 jetta gl ecodiesel


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 Post subject: Re: Injection Pump Seal Kit: DGK-126
PostPosted: Wed Feb 01, 2012 9:41 pm 
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Turbo Charger

Joined: Tue Dec 22, 2009 1:01 pm
Posts: 985
Location: Michigami, USA
Seems Bosch does not include the diagrams in the box anymore. The nice folks at the shop made a copy of the page in their book.

The diagram is moderately helpful: it gives part numbers, but not sizes. (diagram is now above)

Large image: https://picasaweb.google.com/lh/photo/Y ... directlink

_________________
Have a nice day.


'82 Westy 1.9 N/A - 23.5mpg
'86 Jetta TD - 45-50mpg
'89 Jetta N/A - 51mpg
'81 Dasher Wagon 1.6 N/A - 52mpg
'91 Jetta ECOdiesel TD - motor donor, clean shell & tranny for sale
'84 Wasserboxer - DOA, parts donor

'82 Caddy 1.6 N/A - Sold


Last edited by TylerDurden on Mon Feb 06, 2012 12:15 pm, edited 1 time in total.

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 Post subject: Re: Injection Pump Seal Kit: DGK-126
PostPosted: Thu Feb 02, 2012 5:06 pm 
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Turbo Charger
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Joined: Mon Mar 10, 2003 4:49 pm
Posts: 1584
Location: Springfield, VA
I know this was in a thread somewhere before, but does anyone know the diameter and thickness of the fuel distributor head O-ring? I now have three opened seal kits that I have only used the big o-ring out of and am ready to go buy a large stash of the just the head o-ring. I know there are a few manufacturers out there and I'm sure I can find a distributor to sell me a qty of 10 or 20 of them if I can spec them out. I did that several years ago but just got one sample and now I don't have the dimensions anymore

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Bob

'06 Jetta TDI
'82 Rabbit 1.6NA
Honda, F150, S10 Blazer, '41 Chevy Coupe


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 Post subject: Re: Injection Pump Seal Kit: DGK-126
PostPosted: Thu Feb 02, 2012 10:36 pm 
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Global Moderator

Joined: Wed Oct 30, 2002 10:28 pm
Posts: 6904
Location: north central Iowa
Nice diagram, great to have the part numbers handy so they don't have to look them up.
part#51 has the part number:
1900210154

If you want to find a cheaper source for green viton o-rings that size; it should be pretty easy to measure the slot it fits in, hard to measure the diameter of a floppy o-ring that big.

I ordered a couple extra of those too,.. to fill in partial sets.
I think I stretched one too far trying to put it on without pulling the pump end all the way off.

_________________
'91 Golf gasser converted to turbo diesel.
'83 Rabbit gasser, converted to diesel, then converted to run on vegetable oil.
2, '84 GTI projects cars


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 Post subject: Re: Injection Pump Seal Kit: DGK-126
PostPosted: Fri Feb 03, 2012 5:47 pm 
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Turbo Charger
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Joined: Mon Mar 10, 2003 4:49 pm
Posts: 1584
Location: Springfield, VA
Thanks. I guess I'll have to go get dirty. I can find the Bosch number on line for about a buck each but I can't tell if they are viton.

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Bob

'06 Jetta TDI
'82 Rabbit 1.6NA
Honda, F150, S10 Blazer, '41 Chevy Coupe


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 Post subject: Re: Injection Pump Seal Kit: DGK-126
PostPosted: Sun Feb 05, 2012 12:36 am 
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Global Moderator

Joined: Wed Oct 30, 2002 10:28 pm
Posts: 6904
Location: north central Iowa
I think green means viton.
Carbon added to it can make it black.

_________________
'91 Golf gasser converted to turbo diesel.
'83 Rabbit gasser, converted to diesel, then converted to run on vegetable oil.
2, '84 GTI projects cars


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 Post subject: Re: Injection Pump Seal Kit: DGK-126
PostPosted: Sun Feb 05, 2012 9:15 am 
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Turbo Charger
User avatar

Joined: Mon Mar 10, 2003 4:49 pm
Posts: 1584
Location: Springfield, VA
I ordered 10 of them from a site on line using the Bosch number. Even if not viton it will work for a while. If nothing else I can seal up my old pump and use it for testing until it leaks again.

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Bob

'06 Jetta TDI
'82 Rabbit 1.6NA
Honda, F150, S10 Blazer, '41 Chevy Coupe


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 Post subject: Re: Injection Pump Seal Kit: DGK-126
PostPosted: Sun Feb 05, 2012 9:52 am 
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Turbo Charger
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Joined: Thu Nov 17, 2005 1:05 am
Posts: 2446
I'm not sure if all the seals in the Bosch kit are viton or even why you are wanting them to be, but the Bosch kit is top quality and every seal in it is rated for use with all of the diesel fuel formulations including biodiesel and they all have been since the mid-90s.


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 Post subject: Re: Injection Pump Seal Kit: DGK-126
PostPosted: Sun Feb 05, 2012 4:21 pm 
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Turbo Charger
User avatar

Joined: Mon Mar 10, 2003 4:49 pm
Posts: 1584
Location: Springfield, VA
Agreed, I'm not really hung up on viton and every seal I've had leak has been on an old pump that probably had lots of miles on it. I have heard repeatedly that the ULSD eats older seals but again I'm not too worried about longevity at this point. If I get 10-20K miles out of a seal, that's 2-4 years of normal use for me. I suspect I'll get more than that from the Bosch seals.

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Bob

'06 Jetta TDI
'82 Rabbit 1.6NA
Honda, F150, S10 Blazer, '41 Chevy Coupe


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 Post subject: Re: Injection Pump Seal Kit: DGK-126
PostPosted: Mon Feb 06, 2012 12:17 pm 
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Turbo Charger

Joined: Tue Dec 22, 2009 1:01 pm
Posts: 985
Location: Michigami, USA
Edited original post to include annotated picture and parts table.

Please post any confirmed part numbers, so we can add them to the table.

Sizes would also be good. :D

Thanx.

_________________
Have a nice day.


'82 Westy 1.9 N/A - 23.5mpg
'86 Jetta TD - 45-50mpg
'89 Jetta N/A - 51mpg
'81 Dasher Wagon 1.6 N/A - 52mpg
'91 Jetta ECOdiesel TD - motor donor, clean shell & tranny for sale
'84 Wasserboxer - DOA, parts donor

'82 Caddy 1.6 N/A - Sold


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 Profile  
 
 Post subject: Re: Injection Pump Seal Kit: DGK-126
PostPosted: Mon Feb 13, 2012 5:33 pm 
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Turbo Charger

Joined: Tue Dec 22, 2009 1:01 pm
Posts: 985
Location: Michigami, USA
I will concur with those who say change all the seals while you have the IP out of the car.

I changed the cold-start seals and 4 days later, other seals started leaking. :oops:

_________________
Have a nice day.


'82 Westy 1.9 N/A - 23.5mpg
'86 Jetta TD - 45-50mpg
'89 Jetta N/A - 51mpg
'81 Dasher Wagon 1.6 N/A - 52mpg
'91 Jetta ECOdiesel TD - motor donor, clean shell & tranny for sale
'84 Wasserboxer - DOA, parts donor

'82 Caddy 1.6 N/A - Sold


Top
 Profile  
 
 Post subject: Re: Injection Pump Seal Kit: DGK-126
PostPosted: Thu Nov 15, 2012 10:52 pm 
Offline
Turbo Charger

Joined: Tue Dec 22, 2009 1:01 pm
Posts: 985
Location: Michigami, USA
I got the large o-ring for the HP head installed on my Dasher IP. (1.6 NA) That went smoothly.

Looking ahead to some of the other seals, but not 100% which go where. The

I'm pretty sure that "O" is the o-ring for the governor shaft.

"P" is a bit of a puzzle, since the part-sheet indicates only two pairs of o-rings (66 & 30+36). The "P" o-rings seemed identical, and the proper size for the CS lever shaft.


Any info on which/where is appreciated. :D

_________________
Have a nice day.


'82 Westy 1.9 N/A - 23.5mpg
'86 Jetta TD - 45-50mpg
'89 Jetta N/A - 51mpg
'81 Dasher Wagon 1.6 N/A - 52mpg
'91 Jetta ECOdiesel TD - motor donor, clean shell & tranny for sale
'84 Wasserboxer - DOA, parts donor

'82 Caddy 1.6 N/A - Sold


Top
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