It is actually much worse then you think. The Guys over on this other Forum are useing adjustable Reamers (not the the ones that expand) but the ones that the Blades Side on. And, on one person came up with any sort of Guide.
I think with no guide it is tough to do accurate job unless the Bushings a already round inside.
Then the other problem is that no one knows what the Clearence Spce really is.
I posted at the tail end of this thread. I go by 300Dman there and at Benzworld
VWDieselParts.com • View topic - injection pump shaft bushings
This one mentions the .001 shaft Clearence but does not say if that is the total Clearance the Clearence on each side of the Shaft
VWDieselParts.com • View topic - I'm rebuilding my Injection Pump!
In this one the guy mounts said fabricated a one piece bushing and replace the 2 piece ones with that and has pic showing the Pump Housing mounted in a Lathe and a Reamer in the Tail Stock. He just said He used a 17mm Reamer no other details.
The Volvo IP housing has a port between the Drive Shaft Bushings. If that Guy made a one piece Bushing He made no mention of the need for that hole?
Vanagon Syncro Project: Search results for Fuel Injection Pump
Since the present total Clearance on My old Bushings is 0.0084" If I get the 0.0034 Clearance that I got on the Aluminum If not to spec I would at least be better off than before.
I am thinking that My Bushing Wear allowed too much pressure to reach the Shaft Seal causing it to grip hard on the Shaft. The Shaft is grooved and you can see the Seal in the Pic. I have never seen a Seal Failure like that on anything.
Also the Seal is 5 Years Old and made of Viton.