Fuel Pump Rebuild - Replacing the rubber seals ...

[JHR9891]

Hi folks

This one will hopefully prove useful to someone at some point so I figured I would share the love. I recently had to rebuild my fuel pump which resulted in my finding out that both rubber seals to the pressure regulator and the interface between the fiter and the metal housing were shot.

Looking at the Suzuki parts catalogue I found these to be monsterously expensive however replacing them isn't particually trivial as they are a bit of an odd size.  It's been muted that the ID is around 8mm and the OD is like 14mm or something like that. The cross section (thickness of the ring) is about 3-3.5mm but this isn't as important.

In the end I ordered some nitrile o rings from www.simplybearings.co.uk:

1. 3mm Section 8mm Bore NITRILE 70 Rubber O-Rings - I ordered these having read another thread here where someone had measured the ID/OD of the washer. These are a reasonable fit but a little loose IMO.

2. BS203 3.53mm Section 7.52mm Bore NITRILE 70 Rubber O-Rings - The ID on these is 7.52 rather than 8mm.  These fit quite a bit better, especially on the bit that interfaces between the pump file and body. It's a pretty tight fit. They are also have a thicker cross section.

You can order in packs of 5 and the whole lot cost me £10 with plenty of spares. You can order in packs of 2.

If nothing I hope this helps someone avoid this pain in the future. Happy hunting !