2003 TDI IP Swelling Seals
 

#2 tank: 80% VO 20% Kerosene, heated to 160*F at the IP lines, 1 micron absolute filtered.
#1 tank: B50 (Diesel) filtered to 1 micron absolute.
Daily drive of 10-15 miles on the B50 blend.
In the WI cold, I drive an old gasser.

I understand the issue of IP seal swelling when switching from B100 to Diesel & back. The question is: What is the effect on IP seal swelling when switching to the 80% VO / Kerosene blend on trips & then back to the B50 blend?

to try to answer your question:

it swells and then contracts

id just watch it and switch to viton if it looks bad


TDI Fuel Pump Seals Failure? - TDIClub Forums

I hada 03 Golf TDI that I ran B100 on for long periods of time...during trips that had to drop to B20 or so, and midway thru owning the car the switch to ULSD happened too. I never saw swelling (just keep your WVO dewatered or your fuel temp. sensor will short out).

That said, I have a friend running high blends of biodiesel who switched to just ULSD for trips (w/o additives) in his Benz, and had pump seal problems. ULSD has far lower lubricity, so I'd be more concerned with that if you somehow stop running bio blends in your #1 tank.

Thanks for the replys.
So am I wrong to conclude that switching from B50 to VO 80 + kerosene will not adversly effect the IP seals on trips with B50 for DD use?

IMHO the lubricity of the biodiesel should temper the seals. However, do check out TDIClub, it's an incredible resource, and there are a whole bunch of people there running WVO and biodiesel.

Thanks.
I'm a member of TDIClub & several other forums dealing with diesel alternatives. I try to get several views on anything that can break & cost me $$$$$$$$$$$$$$$$$$$!

lot of things can break and will cost a lot of money


preventative maintenence is key i guess

just keep a watchful eye for small leaks

Oh, the only other tricky thing is there's a special triangular bolt on the top of the IP (as a security bolt) that's marked by yellow paint. If you need to open up your IP, the dealer will know and it will most likely void your warranty (if it still exists). The tool for the bolt is made by metalnerd, and I actually have one I think from my TDI days. PM me if interested.