| The Bosch D-jet fuel pump has a common
leak problem. The drawn steel motor case is flooded with gas (to cool and lubricate the motor). This case is sealed via
a small O-ring in the aluminum part that presses into the case. This O-ring gets hard and brittle with age and cracks.
The result is that the pump appears to leak fuel out of the electrical connector on the side of the case
(it's not really leaking there, but the fuel runs down and drips from the connector). This can
be fixed easily by opening the case and replacing the O-ring. Unfortunately, the motor case is crimped (in 4 places) to the
aluminum part. These crimps must be pried back to slide the motor case off. It's difficult to pry the crimps back w/o
damaging the case. I built a small prying tool for this purpose. It's a short piece of 1/4" steel rod (music wire) that
has been shaped with a bench grinder as shown. |
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