Help - Split 16V Fuel Pump Housing

[Brad H]

Hi all,

Have been frantically searching the internet for a replacement housing for the main fuel pump for my 1988 16v.  Recently replaced both fuel pumps after the lift pump failed a year ago (got it working again after cleaning connections in tank), which seems to have sped up the demise of the main pump.  Anyway, once the new pumps were fitted, after a short drive, I found petrol was pouring (10 drips per minute) off of the housing.  The o-ring seal is fine, but the fuel seems to be coming from the top of the housing.  I will strip it all off to see exactly where the leak is coming from but if it is the housing, it would appear that I'm stuffed as they no longer manufacture them and everywhere seems to be out of stock.  Any ideas greatly received.  I believe from the threads on here that a Mk3 tank and pump swap will not work on the 16v due to the lower pressure not being sufficient for the K-jetronic system??

Thanks in advance...

[roberto]

it could just be one of the return hoses split. but if it is the casing that's split you could fix it with araldite. you would have to drain it completely of fuel then roughen up where its split with a grinder or dremel to provide a really good key for the araldite to stick. I repaired one with fibreglass resin before and it was fine(didn't have araldite at the time). oh and the mk3 pump is no good on k-jet.

[SimonG]

You may struggle to find one new , so second hand is possibly going to be the only way.  Check classifieds, put out wanted ads, etc for one.  Be cautious though, a lot of people seem to want to sell them overpriced so I wouldn't jump too quickly.

Hopefully it's not the housing and instead, a pipe that might not be seated properly or has split as previously mentioned.

[Brad H]

Thanks both for advice.  I'll lower it from the floorpan and aim to run the car with it lowered so I can see exactly where the leak is.  The unit was replaced about 10 years ago and the car has only done about 10K miles since then.  Although it might be that time causes the wear-and-tear and not mileage..  Have heard that ethylene that has become more prominent in petrol which might be causing the issues with older materials selected for the purpose when the petrol mixtures were different.

[roberto]

it might be worth trying to graft the k-jet pump in to the mk3 pump housing inside the tank?

[Brad H]

That's a possible solution I guess but not sure how the pump would achieve the same effectiveness in that position. I'm hoping to lower, test and strip this weekend if time allows. If it is definitely the housing I might try making one in fabricated stainless steel. Wonder if there would be any interest in making larger quantities of these?

[gazareth]

there is only one way to find out. advertise them first before you make them