Hi all,
after I've been struggling with that EPIC pump's wiring and the rotor sensor gasket the bloody thing is leaking again. This time the source has been diagnosed as the sensor (7186-009-8) itself: diesel is leaking between the casing and the resin.
This actually seems to happen to others as well, I've found some references in this forum - but unfortunately no solution yet.
I've tried to grind off a bit (1-2mm) of the resin and fill/seal it back with JB Weld - which worked for some time, but it started leaking again at an edge. I tried a replacement sensor (hard to find one!) but that leaks more than my original one. Which makes me think that maybe the pump itself is damaging the sensor. Is it correct that the rod that moves inside the sensor touches the end and has to be pushed against the spring about a millimeter or two when installing the sensor? I suppose if that rod was off by so much, the ECU would signal an error though.
How much pressure is the sensor supposed to withstand? Could a leak test with an air compressor have damaged the sensor?
Does anyone know how these sensors look like internally, i.e. where is the leak usually located? By looking at the bushing I can't see any obvious position that could leak, this seems pretty solid to me. Is the resin supposed to actually be the seal or does this just keep everything in place? Is that black ring with the allen bolt shape (or the two holes, for older models) supposed to be removable? Would removing it be of any help?
Even though trying to get this done from the outside may seem futile, my next attempt would be to remove even more of the resin (which seems dangerous when you don't know what's hiding inside) and fill it again with JB Weld, or maybe something that's less viscous. Any recommendations for a resin that resists diesel fuel? I'm also considering to apply some pressure through the plate that's usually installed on the four outputs of the pump, but due to the shape of the sensor (that bump on the back) I'm not sure how this should work.
Any more hints on what might help sealing the sensor?
Cheers
Sascha