There is some kind of hole on the bottom of the pump that is leaking fuel, plus the rear of the pump somewhere is leaking, and the diaphram by the fuel pin is leaking. Does this mean I may need a new IP before long or is it just a wonderful side effect of ULSD? Now after it sits a few hours its hard to start because the fuel has leaked out and it has to reprime itself. Time for a rebuild?

 

IMHO multiple leaks tells it all. They do not fix themselves. If you can take it out yourself I know a super pump shop that does ours for less than $400 .

 

Where is this shop located? I was thinking about a 230hp BD pump. Any special tools needed to remove the IP?

 

If you're on a budget, BOSCH P/N DGk-121 will get you a complete re-seal kit. You'll need a puller to pop the gear off the pump. Beyond that, basic hand tools will get the job done.