Leaky diesel pump pressure sensor

[$hitblast]

It turns out the diesel pressure sensor on my diesel pump is leaking. The sensor sits in the middle of the four injector lines coming from the pump, and it's leaking several drops of diesel per second with the engine in operation. With two lines disconnected from the pump, it was possible to get at the sensor with a 17 mm open ended spanner.



The metal holding onto the plastic where the wires connect has several cracks around the rim. The wires, as you can see, are not insulated near the sensor, and they are even entwined. I wonder if it is supposed to be like this. Turns out it can be ordered from Germany for 551 USD. A bit expensive. Can I just put in a regular screw?

Edit: Part number 1467200303

Edit: Well, the twisting of the wires happened as my friend unscrewed the sensor, and likewise the de-insulation of the wires, so please disregard that info. Sorry about that.

[$hitblast]

Having browsed the Net for a few hours, it seems this plug isn't doing much, according to these threads:
aaz fuel pump wiring - The Brick-yard
AAZ injection pump wiring? - TDIClub Forums

It's tempting to stop the leak by blocking the mound of this thing with some epoxy. Knowing the cost of it, I'd ask you guys first.

[gldgti]

Yes, just block it somehow - or you should be able to fit a bolt withthe same thread and a copper washer - even better.

[$hitblast]

presumably SOLVED

Got it working again yesterday. After going through three auto-parts-stores, the junk yard and six hardware-stores, I found a matching bolt at the seventh. It was a little too long, but the right length with five washers added. I used three diesel-resistant plastic-washers, interleaved with two steel washers. The guy didn't have any aluminium or copper washers. It's a metric bolt, 8x1 mm. I had to tighten the bolt quite well, as there was at first a fine spray-mist leaking through.

It took a little less than a minute of churning to bleed the air out of the injector lines. I then tightened the nuts on the lines by the injectors, and churned for another minute, before it finally started and ran just fine. I drove it about ten kilometers in normal operation. I'm going to start it up again today, and see if it's easier to start than before.

[gldgti]

tip for easy priming (works EVERY time) - take off the fuel return hose and blow into down it to slightly pressurise the tank... its hard (like blowing up one of those party clow balloon things) but just blow until you see fuel going into the pump, then hold your finger over the end to keep the pressure in. Wait until some fuel comes out of the return outlet on the pump, and the just reconnect the hose. Should be only a few cranks until it fires up!

[$hitblast]

Thanks for the tip, Gld. I'll try it next time I have the chance.

My car is starting a little different than earlier after this fix. It used to only crank once or twice before starting in the summer; and this without glowing. Now it cranks about five times after glowing with three new plugs. I wonder if I could adjust this by screwing the new bolt somewhat more or less.