Leaky Injection Pump
 

As soon as we switched over to the new, improved, cleaner diesel fuel, my pump started leaking profusely from the top where the injector pipes attach. I've never had my pump off, or apart, but I also need to change some other seals (like the o-ring for the shut off lever, that's been leaking for a couple of years)

Is there a seal kit that I can order to fix these leaks? Do I need any special tools? or do I have to worry about getting anything out of calibration? I have advanced mechanical skills and have rebuilt engines and auto & manual transmissions and even a SPICA injection pump on an Alfa, but I've never had a Bosch pump out of the car.

Vielen Dank!
Reid Zeigler
'92 300D 2.5T with about 260K miles

Pumps are pretty techincal to work on, as in DIY rebuild.

Your leak sounds like delivery valve seals. Search for replacement instructions and torque procedures. Not too hard and ~$5-6.00 in parts for o-rings and crush washers. Shutoff valve is probably an o-ring seal.

Neither requires pump to come off car.

Assuming your pump is similiar to a 99's, you'll need a $50 special tool to get those "injector pipes" off. Is that really the proper name? Call up Fastlane Phil, he'll get you setup proper.

spline tool
 

If you need the spline socket you can gat a loaner here from Dieseldiehard. It is an easy job. put some fuel conditioner or bioDiesel in and see if that helps the rubber o rings bounce back to shape and get you down the road.
The best place for the crush washers and o rings is The Bosch service center. Most major cities have one. Just give them the numbers on the side of your pump.

really easy job to replace the delivery seals.

parts and socket are available at the dealer,35$ for socket just cents for o rings good luck!