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]

REASSEMBLY STEP 2

fitting the port housing inner plate & brush holder.
i retained the starlock (or quicklock) washers when i disassembled.
took them off carefully so good to reuse.
if you damage the starlocks get some new ones.
i flattened the starlock tongues using a very small socket to get them to preload again.
i used a slightly larger socket to push them down on the securing pins.




next i resoldered the spring wire connectors to the brush housings.
carefully move the wires into position and push the hook ends through the slots/holes in the connection plate.
i used my original disassembly photos for reference.
fairly easy to see where the wires must go using logic.
very difficult to make errors such as crossing the wires up accidently.
both stay on the sides of the electrical plug they come out of underneath the brush plate.
i did have to melt existing solder out of the holes before i could clip the wires in.
once clipped solder these connections.
soldering went much better than the earlier frustrations i had with the earth wire in plug base.





i repeated the same with the 005 pump i am reassembling.
had to do a bit more work on that one.
different style of brushes and electrical connections on the earlier 005 pump.
one of the brush connections needed some more securing solder repair.




after soldering clean up any loose solder drips, blow out with air and electrical cleaner,
you don't want anything trapped inside this assembly that could later break loose.