i thought i would post this how to with photos( as best i can) i had the dreaded leak and came to this site, and read some posts which were very handy, just thought i would share what i got up to today freezing my ass off. i changed the o ring and bush, some change just o ring, some o ring bush and spindle, (price is the thing, and how worn the parts are)
STEP 1. if you need the number from the pump, you will need to take off grill remove fans from rad unclip rad and move to one side. the numbers are a bugger to see if you dont do this, the numbers are facing down wards on the side of the pump in tiny writting i tried a mirror but couldnt see, you will have lots of room to get at the pump so do it any way.
this is my pump 1.9 non turbo, turbos have some extra cubbings, but should be simalar
STEP2. on top of the spindle with the 10mm nut there should be a grove, mark the position of the groove/line, so you can put it back where you started,( i diddnt do this, but with a bit of trial and error got it right again) this next pic is the spindle with the groove/line
STEP3. pop off the throttle cable and dampener bar thingy, undo banjo fitting. shown on first pic blue pipe going to pump. 17mm i think, carefull not to loose 2 copper washers, i put the bolt back into pump with washers
STEP 4. undo 10mm nut on the leaky spindle and remove the arm and return spring which will be under tension, you should have a nut,washer,2 plastic spacer things and the spring, remember how they go, maybe lay them out in order.
STEP 5. remove throttle cable bracket, there is a spring to a lever at the back of my pump, i think its for the manual choke, that just pushes off. undo the 4 allen bolts holding case on. there is a little spring inside that has to go back on to the main pump from the casing when refitting.
this next pic is the spring inside the case.
and the next pic is where it clips back on
STEP 6. i took the spindle off to replace the o ring, the spindle is atached to a spirng thing, the whole unit just turns up and slides out, if you are going to go whole hog replace spindle unit, i removed old o ring, cleaned the groove and replace o ring.and
STEP 7. the bush. my old bush was brass the new one black steel, i had the old bush driven out and new driven in at the place a got the o ring and bush from, you could do it yourself but carefull not to braek the casing, it cost 20 quid all in bush replaced and parts.
next pic is black steel bush poking from top of casing
STEP 8. remove this bolt thing for refitting its very important to remove it with out adjusting it. must be taken out with the nut DONT unscrew it form the end
undo from where my index finger is not the screw on the end, its somthing to do with the fueling, the reason to remove it is,it pushes against a spring lever in the pump and the case will be tricky to get back on. next pic is the bolt thingy inside casing
next pic is lever where bolt thingy pushes against
STEP 9 right the spindle has been replaced or o ring replaced and spindle refitted if removed, and the bush has been replaced in the casing, clean both faces of body and case, lube the spindle and new o ring, cos its gunna be a tighter fit than the old nackerd one, i used diesel (there will be plenty sat in the pump).
STEP 10. put the whole lot back together.
start by conecting the little spring from case to pump, slide spindle up shaft/bush, it might be tight on the seal, so i tempery put the throttle arm plate on and tightend the 10mm nut which pulled the spindle up through the bush and then took the arm off again.
so now the spring is conected inside the pump and the spindle is up inside the bush. put your allen bolts back in and tighten, put your fuel bolt thingy back in the side of the pump, put your banjo fitting back on, spring thing at the back of pump just pushes back on, throttle cable arm back on then put the return spring and plastic spacers and the throttle arm plate with line in the spindle in right place and tighten 10mm nut. the return spring on the throttle plate is a bit of a bugger but not to bad, i think thats it.
fire her up for a test and put the rest of the van back together