Suddenly won't start after recent tandem pump change

[johnyfartbox]

ok .
taken the pump off yet again.
thats another gasket gone, got one left.
here is two photos of the pump ive just taken off and the block where it sits.

Not sure but at the bottom it seems there is something weeping. maybe drawing air in as the crank is turned hence the air bubbles.

Putting the old LUK pump back on and it sitting snug, there is no slight wobble on the pump. But when I put the BOSCH pump on and it feels snug so has located correctly there is a very very slight wobble as though it is not sitting flush with the block.

 

[johnyfartbox]

this is the pump I bought off ebay.

Bosch Vacuum Pump F009D02799 | eBay

Bosch Fuel Pump F 009 D02 799. We are an authorised distributor for Bosch parts. Equivalent to Part Numbers: Audi: 038145209Q <br>Seat: 038145209Q <br>Skoda: 038…. If you order before 12PM we'll dispatch same day from our UK warehouse. For guaranteed next day delivery please select this option...

www.ebay.co.uk

 

[johnyfartbox]

Now here is something that might be causing a problem......maybe.
In this photo you can see the height of the collar on the BOSCH pump thats the bit that slides into the location hole in the block.

And here is the LUK pump.

Ummmmm.

 

[Catnip64]

Might just be the design of the casting.
The key dimension is the highest point on the drive dog to the gasket mounting face, check to see if it's the same on both pumps.

 

[JHB]

I had exactly the same problem when I changed from LUK to Bosch on my LHD TDI90. The bosch pump just didn't sit well with a bit of rock against the mating surface. Turned out one of the lugs on the pump casting was fouling on the water hose connection that is screwed into the block. A few minutes filing the pump down and it fitted absolutely snugly

 

[johnyfartbox]

I had exactly the same problem when I changed from LUK to Bosch on my LHD TDI90. The bosch pump just didn't sit well with a bit of rock against the mating surface. Turned out one of the lugs on the pump casting was fouling on the water hose connection that is screwed into the block. A few minutes filing the pump down and it fitted absolutely snugly

I'll look into that thanks.

 

[johnyfartbox]

At least now I can properly tourqe small nuts and bolts up.

 

[JHB]

I'll look into that thanks.

Yes. I was completely flummoxed for a while, but when I removed the new pump and inspected it I could actually see the marks in the aluminium where it was fouling.

 

[DuncanA2]

I would really love to see where the bit of filing has to done. I am preforming this procedure shortly, so anxious to know. Thanks in advance.

Cheers Duncan

 

[CrispyEdd]

I've fit two boach pumps recently, one to tdi 90 atl with the intake spacer and one to an amf. Both worked well and no mating issues. This sounds like rotten luck with casting of the housing on the pump then. Hope you come back with good news jonny.

 

[JHB]

I would really love to see where the bit of filing has to done. I am preforming this procedure shortly, so anxious to know. Thanks in advance.

Cheers Duncan

Hi Duncan You can see the hose that the pump fouls on in one of Johnny fartbox photos. The interference really is next to nothing (but enough to skew the pump) probably about 0.5 mm. The casting has a draught taper on it which forces it to lift as you try to fit it. On my car the hose fitting into the block is a hex head and I suspect that if it's tightened so that a flat is against the pump it's OK, but if a point is against the pump it fouls. Either way filing away a small bit of aluminium gives clearance

 

[johnyfartbox]

I've fit two boach pumps recently, one to tdi 90 atl with the intake spacer and one to an amf. Both worked well and no mating issues. This sounds like rotten luck with casting of the housing on the pump then. Hope you come back with good news jonny.

I've emailed the seller with an explanation and photos of each pump where there is a difference
I'll keep all updated.

 

[Howey]

Would 2 gaskets get around this problem??

 

[johnyfartbox]

I've actually thought about that but if one gasket is sufficient under normal circumstances then over coming the problem is the way to go.

 

[CrispyEdd]

Such a vital important part and expensive, so needs to be 100% and fitted correct. Best of luck sorting it out.

 

[johnyfartbox]

Thanks Edd

 

[dj_efk]

Would 2 gaskets get around this problem??

In my experience - this is never the answer in any application where the manufacturer doesn’t specify it.

 

[dj_efk]

Hi Duncan You can see the hose that the pump fouls on in one of Johnny fartbox photos. The interference really is next to nothing (but enough to skew the pump) probably about 0.5 mm. The casting has a draught taper on it which forces it to lift as you try to fit it. On my car the hose fitting into the block is a hex head and I suspect that if it's tightened so that a flat is against the pump it's OK, but if a point is against the pump it fouls. Either way filing away a small bit of aluminium gives clearance

Thanks so much for this - I think anyone upgrading their ATL from LUK to Bosch pumps should be made aware of this to save the heartache that Jonny has gone through - assuming this is indeed his issue.

 

[johnyfartbox]

Hi Duncan You can see the hose that the pump fouls on in one of Johnny fartbox photos. The interference really is next to nothing (but enough to skew the pump) probably about 0.5 mm. The casting has a draught taper on it which forces it to lift as you try to fit it. On my car the hose fitting into the block is a hex head and I suspect that if it's tightened so that a flat is against the pump it's OK, but if a point is against the pump it fouls. Either way filing away a small bit of aluminium gives clearance

Do you mean here?

 

[johnyfartbox]

For those that are not aware of what the Bosch and LUK pump look like side by side check this out.

Bosch on the left.
If this is the Bosch equivalent and correct replacement for the LUK , it dont look the same has the LUK.
Thoughts??

Here is a Bosch pump on Amazon.

Bosch F009D02799 Vacuum Pump : Amazon.co.uk: Automotive

Bosch F009D02799 Vacuum Pump : Amazon.co.uk: Automotive

www.amazon.co.uk