Fuelpump rebuild: Bosch 0 580 463 009, Fuel pump - 1974 1.8 Options

[wonkipop]

think this is the right section of the website to put this in.
even though its a spanner job, the material is historic and possibly of esoteric industrial archeology interest. who knows?
1.

background.
i recently recommissioned my 74 1.8 after nearly 16 years of storage.
i paid for storing but i always knew i would. complete rebuild of fuel system.
we got the original fuel pump to come to life but it bled from every orifice.
flow rate was ok however and motor still worked fine - just a minor fire hazard.

2.
action.

to get the car up and running we took out the original 0 580 463 009 fuel pump and re-plumbed for a modern two port in line pump. car runs.
having done that, in some ways i felt the plumbing was a little compromised over the original given the pump needed to be repositioned to have a line in the back as well as out the front making the line out a pretty tight turn to get up into the engine bay. but it runs.

3.

delayed dream due to thoughts of it being a nightmare.
in the back of my mind was the idea of rebuilding the original fuel pump.
general consensus down here at the bottom of the world (aus) was don't bother, its a sealed unit and unserviceable.

4.

then. a young guy with a 1970 citroen DS21 IE inspired me. he had taken his similar bosch 3 port pump apart and rebuilt it proving its possible if you are determined enough.
i think the pump in the citroen was a 0 580 463 005, which the 009 replaced
not sure when the 009 came in, but its before the 010 (which is the completely different pump and fitted to the later 75 and 76 cars - amongst the first of the in line 2 port types). maybe the historians know exactly when 009 kicked in, i'm guessing it comes in with the L jetronic in 74 model year, but it could be earlier. externally a 005 is indistinguishable from a 009. i might have discovered the difference internally in what i have taken apart to date.

TAKING the 0 580 463 009 apart.

STEP 1.
undo the 4 screws securing the pump and outlet housing on top of the unit.
keep it all upright and vertical.
remove the top part of the housing.
remove the upper o-ring.
remove the metal pump vane and the five cylindrical magnets housed in it.
(bag them so you don't lose them - they seem to be weakly magnetic cylinders).
remove the vane housing.
remove the lower o-ring.

If your pump is only leaking from this upper housing its an easy fix.
just replace the two o-rings and put it all back together.

Don't need to post pics of this stuff its very simple to do.

the o-rings are 30x2mm i believe. could be 31x2mm. yet to confirm.
still to make the trip to the specialist o-ring shop here in melb aus.
i'll be looking to find the best fuel resistant o-rings i can get hold of.

suprisingly these o-rings were still in good shape in my pump and were not the source of the leaks. but i will be replacing them.

[wonkipop]

POST SCRIPT.

there are a couple of similar 3 port fuel pumps lying around in the workshop which have been thrown at me to investigate, given i got the 009 apart.

one is a 005 that was taken out of a 1974 SAAB EMS.
externally it looks mint. I'm not sure where these were located on a SAAB but must have been a protected position. the pump has been tested and it is below flow specs at 700ML per minute. (for a 914 the flow rate is 50L/hr or 833ML/minute).

the other is a similar type of bosch unit that came out of mercedes 600 series.

It took me a day to take the 009 apart, but i took my time and thought about how to do it. It took me less than two hours to get the mercedes unit apart to almost the same level of disassembly, felt confident with the method - though the mercedes unit was a lot more unwilling to ease the outer casing shield apart from the upper port casting. it was in their tight. It was interesting once you got inside it. the motor has what i would call turbulence shrouds top and bottom. white plastic shrouds. these encase the coil windings armature section of the motor. I have seen images of the interior of the citroen fitted pump and the motor had only a top shroud not a bottom shroud. I'm not sure if the citroen unit was a 005 pump but i think it might be. I have yet to take apart the 005 pump that came out of the SAAB so that might be interesting to see if it has a turbulence shroud, either completely like the mercedes or a half unit like the citroen. The citroen ran D-Jet fuel injection.

the mercedes pump has a different arrangement in terms of its pump head, ports and o-rings than the 009/005 units fitted to the 914s. so its not an exact comparison - but i believe early VW bosch fuel pumps for EFI have the fully shrouded armarture similar to the mercedes unit.

in pulling the mercedes pump apart we found the reason for the failure. the electric motor commutator had worn to such an extent a portion had broken off and jammed against one of the brushes preventing the motor from rotating. we might try and get the commutator and brushes rebuilt/renewed if we can find someone who can do it for a reasonable cost. you can still get these pumps new from mercedes but at horrendous cost. so its kind of worth having a go at rebuilding them. anyone rebuilding a 005/009 fuel pump from a high mileage 914 will likely find similar advanced wear of the commutator and brushes and would need to rebuild those parts if they wanted to renew the units.

once i get the SAAB one apart I'll post some images.