Originally Posted by Diseasel300

The time had finally come to do something about the oil leaks on the injection pump on this car. I have no leaks from anywhere else on the engine or transmission other than the side cover of the injection pump. For whatever reason, finding a seller in North America who sells the resealing kit is impossible (I looked for 3 days, none even on eBay that are domestic).

Tired of the oil drips on driveways, I decided to cut my own gasket for the side cover. Luckily I still have the carcass of the original IP off the engine, so I used the side cover from it for sizing and template design. I settled on using high temperature silicone gasket material since it should resist hardening in the future, certainly longer than the original rubber seal.

You can see the pix below of my gasket compared to the original rubber one (which is FIRMLY attached to the side cover and hard as plastic).

During the replacement process, I noticed that my stop lever was leaking a fair bit of oil too. I've replaced the O-ring in the past and lacked success. I found a writeup on PP's parent website saying the OEM size was 8mmID x 2mm. Unfortunately that information is wrong, that's what I had in there and it's a very loose fit. I went the next size up to 8mmID x 2.5mm in Viton and got a nice snug fit without causing any binding.

After getting everything put together, I used some of my fabulous Oil-Eater degreaser and hosed the engine down. Took the car on a nice HARD romp on the interstate and I'm pleased to report that the IP is still bone dry! Time will tell how long it lasts, but the depressions in the engine mounts would fill with oil after a week or two of driving - that's how bad the leaks had gotten. My driver's side engine mount is wasted from all the oil that's been leaking on it too, just another job for the fall.

On the way home, the odometer clicked over to 186K miles as I turned onto my street. Seemed fitting as a milestone marker