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Model specific boards => Golf mk2 => Topic started by: philstar on 03 June 2017, 17:12

Title: Fuel pump query
Post by: philstar on 03 June 2017, 17:12: My golf has been stood for a year, I have just done a load of welding on it for MOT and I started it today to find a big leak coming from the fuel pump underneath:

https://goo.gl/photos/WvDWnKXU56qSezcT7 (https://goo.gl/photos/WvDWnKXU56qSezcT7)

https://goo.gl/photos/t2Qw1zDgkcV6iMaKA (https://goo.gl/photos/t2Qw1zDgkcV6iMaKA)

Does this look like your bog standard worn out o-ring scenario, and is it the right pump for my car? I have an 88 small bumper 16v k-jetronic.

Is it ok to remove it or do I have to de-pressurise the system first somehow?

Are genuine spare parts still available for this fuel pump?
Title: Re: Fuel pump query
Post by: lemski on 03 June 2017, 22:01: You could probally get a seal for it from maybe tps or vw heritage.
Looks like the kjet style pump
Title: Re: Fuel pump query
Post by: philstar on 04 June 2017, 18:42: Well I tried to remove the fuel pump, but the philips head screw above the pump had been rounded.

So I tried to take the combined filter-pump-swirlpot mechanism off, but the mounts all broke.

So I took everything off including the mount. Why is it made of plastic?! The swirl pot housing is broken. The swirl pot is covered in 30 years of rust. I know the pump works fine but the housing must have distorted to cause the leak because the o-ring is in great shape. Perhaps I generated too much heat near it when I was welding. Another great Sunday.

I just hope I can get good quality new parts...
Title: Re: Fuel pump query
Post by: lemski on 04 June 2017, 22:43: You wont fi d the housing. They are rare. Second hand demand high money aswell. Maybe yours can be reheated and saved or sonething.
Title: Re: Fuel pump query
Post by: philstar on 05 June 2017, 10:45: OK here's the situation. The pump retaining collar shows a gap at the base when joined to the housing:

https://goo.gl/photos/TZ8o4R6yzauNXQCC9

A new seal might pad it out and a bit and stop the leak but I'm not confident.

The accumulator has a pinhole at the base:

https://goo.gl/photos/d5WvQ3Sa1iYvaSNK7

I'm sure I can weld this up?

The union nuts are in a right old state:

https://goo.gl/photos/6MZft1VcRqiKb4KfA

I know goodridge sell a stainless steel set of these for £100

Is there an alternative option to spending close to £200 on a secondhand unit? It may sound silly but i'd rather spend £300-£400 on a modern conversion than risk £200 on original second hand items that may fail soon, or not even work on the first place.

Has anybody come up with an alternative solution? Does a system of another car work? My bracket is in good order so I can build a custom mount myself.

Struggling here, I've spent weeks welding and prepping the car so I can't give up now!
Title: Re: Fuel pump query
Post by: philstar on 05 June 2017, 14:46: OK have had the accumulator brazed by magic Malc at TTP Performance in Bromsgrove, and have ordered a new fuel pump seal from THE ONLY supplier I can find, an eBay trader in Athens:

http://www.ebay.co.uk/itm/331623858599

part number is N 903 124 02 (for later MK2 golfs I believe the part number is N 90262802 see here: http://www.golfgtiforum.co.uk/index.php?topic=117876.0)

All I can do now is wait, and prey. Unless someone has experience of another solution which I may still yet need!
Title: Re: Fuel pump query
Post by: philstar on 05 June 2017, 14:49: rubjonny has posted on the clubgti forum:

http://clubgti.com/showthread.php?270543-Golf-gti-mk2-16v-external-fuel-pump-housing

"yes use an inline kjet pump such as mk1 gti, plus an external fuel reservoir. the post-84 mk1 cabrio and scirocco as well as all g40 shape polo have one that is perfect. but any decent 4 outlet reservoir would do you. the main trouble is getting it all under there as you have pump, filter, reservoir and accumulator. the mk3 has a fuel filter carrier which might be handy to start with, or use the old mk2 metal pump carrier to fab something up"
Title: Re: Fuel pump query
Post by: philstar on 05 June 2017, 17:00: For £120 a complete set of stainless steel braided hoses can be bought, made by HEL:

http://auto.helperformance.com/volkswagen-golf-mk2-gti-16v-k-jet-1984-1992

It's either that or buy the two that are damaged individually for around £50-£60.
Title: Re: Fuel pump query
Post by: lemski on 05 June 2017, 21:01: You can ditch k-jet and change management allowing you to then change to mk3 fuel tank in intank pump.
You can change the pump to a high pressure pump and use the accumilator still.
Or you can buy 2 damaged pumps and make a good one out of both.
Peraonally ide get an external high pressure pump in line and keep the accumilator
Title: Re: Fuel pump query
Post by: philstar on 11 June 2017, 16:14: Cheers Lemski do you know where I can find the specification for the pump I would need if I choose to run a new external one? I am just waiting for the seal to arrive from Athens in the hope of saving the original setup but if it fails my next logical choice is to replace the pump.
Title: Re: Fuel pump query
Post by: lemski on 11 June 2017, 16:41: I dont know. All you want to find is an external high pressure pump that can produce say 6bar. The working pressure of the working is set up by the wur and the ketering head sets up system pressure. Or the other way arpund cant remeber but itll never over work the pump
Title: Re: Fuel pump query
Post by: philstar on 14 June 2017, 12:01: Cheers Lemski.

ERROR: THE SEAL I BOUGHT FROM GREECE IS NOT RIGHT FOR MY CAR.
I should have read the measurements!

New seal on the left, old seal on the right:
https://goo.gl/photos/yaN8njGQeXEnFrxr8

I bought N90312402 which is 42mm diameter.

What I need is the later seal N90223802 which is 59mm diameter. My previous post (reply #5) was wrong.
This part is available here:
https://www.mecatechnic.com/fr-FR/joint-sur-pompe-a-essence-principale-pour-golf-2-gti-8s-et-16s-60mm_GC46303.htm

According to this diagram (item #34):
https://volkswagen.7zap.com/en/rdw/golf/go/1988-77/2/201-69000/?vin=undefined#34

There is another part number for PL,RD, and GX engines which is N90262802
Title: Re: Fuel pump query
Post by: philstar on 23 June 2017, 11:27: Fuel pump seal worked! However the housing is now leaking around the top collar which has the two pipe outlets. It is SUCH a pain to get to to check, I've had it off and on twice thinking it might be a loose hose connection. So I'm going to try and repair it using some JB Weld before throwing any more money at it.

All cleaned up and painted, unfortunately the new fuel filter doesn't have the right connections so using the old one:

https://goo.gl/photos/Bgtv9rGWwY6KKS9K9
Title: Re: Fuel pump query
Post by: philstar on 23 June 2017, 13:43: OK I have sanded down and degreased the area around the top of the fuel housing:

https://goo.gl/photos/dqaVV8fGDL7DqsRs7

and applied plenty of jb weld:

https://goo.gl/photos/hMeBmZ8J7nJpWpQ66

I recommend using latex gloves for spreading and cleanup. This is the stuff I used that was already in my garage:

https://goo.gl/photos/mp7jnpKozxhhkrFPA

needs at least 15 hours to set so I should be able to refit the housing again on Sunday.

This is last chance saloon!
Title: Re: Fuel pump query
Post by: philstar on 29 June 2017, 08:43: Fix worked! Car now has MOT after being stood for over a year. Happy days! Never give up!
Title: Re: Fuel pump query
Post by: lemski on 29 June 2017, 08:47: Well done