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.

[Yellowbeard]

I'm working on a similar problem in the US. I've been looking for the O-rings for the face plates (the easiest to get to ones as those seem to fail the most for me).

My part Number is VW 0 580 463 007 FWIW. Looks like it was used in D and L Jetronic fuel systems so that jives. Worth noting that my fuel pump is also licensed to kill. Well, I guess they all are but mine is ACTUALLY James Bond so.... (IMG:style_emoticons/default/wink.gif)

Here are some sizes that might be helpful:

The SAE size appears to be: 1-1/4"x1-3/8"

The diameter of the ring cross section looks like .070.

The standard name for this part seems to be AS568-026

The metric standard size appears to be 2-026

Here's a handy size chart: https://www.rocketseals.com/o-ring-size-chart/

Here's a version of this part at Napa: https://www.napaonline.com/en/p/BK_7272026

If you're in a pinch, Danco (faucet parts) makes an O-ring in this size called the #82. They can sometimes be found at plumbing supply places.

In all my research I also found that you can just buy an O-ring splicing kit (something I'd never heard of) and make your own. Here is an example of that at Amazon:

https://a.co/d/b7cTwcq


Just FYI, I haven't actually tried any of these yet because it's Sunday and I can't get any of them. They don't appear to be available locally for me in any event but at least it gives folks something to search for.

I will update once I actually get something from somewhere and try it.



***EDIT*** Here's what I actually ended up ordering from Grainger: https://www.grainger.com/product/O-Ring-Bun...41UJ75?opr=ILOF