So I got new copper crush washer from Roger today. I still have a leak at my fuel pump.... With help today from a local 928 owner I was able to narrow down the actual problem. The casing of the fuel pump, on the power connector end of the pump, blew out. Not completely but the seal that was formed there is no longer good.

It held good for about 60 seconds or less when I first tested it. I heard a loud wooshing sound as it gave away. Now I am thinking the fuel system got over pressurized and caused the pump to fail. Now the only way that I can see this happening is if my fuel return line is somehow clogged. I ran about a gallon of gas through the pressure release port on the passenger fuel rail before I even attempted to pressurize the system. I know the feed side of the system is good. Does this seem plausible and if so has anyone else seen this happen before? Or am I just sounding like a crazy person. I'm at a loss here and have never seen anything like this happen, but I am young and inexperienced in these things. I need help here guys.

 

Id just say its a bad pump...obviously now so.

 

2nd the bad pump.....however I had LOTS of issues with copper washers leaking & then I torque the crossover pipe from the pump to the filter too much and it leaked too......so be sure to torque the bolts only...not the crossover pipe!!!!

 

+3 on the bad pump. PM me your address please.

 

+4 on the bad pump.




demons and all that

 

Well damn. Was hopeful. How long does it take the system to reach the correct pressure? I may buy a gauge or try to find someone that has one I can borrow next time I test it just so I can see what's happening. I don't know yet. I just remember hearing it as it blew out. Sounds like it was under quite a bit of pressure.

 

is the line plugged at the top of the tank sender?
remove the line and blow in it ,
it should back flow to the pump, what you describe sounds like a plugged line and it caused the pump to fail.

On refitting the pump always use brand new sealing washers,
these are truly one time use.
also put a dab of PTFE sealing paste on the threads of the return valve then insert into the pump.
Dont over tighten the cap nut as it will crush the short hard line and then you will have to start over with new sealing rings and new hard line,
also if your not refitting a new pump then buy a new check valve they are inexpensive

 

Brad,
Got your PM. Sent you one in return. Then sent you another one. Disregard the first reply PM. I found my extra fuel pump and am sending it to you tomorrow. You should have it Tuesday. I tested it and it is good.

 

I always change filters with the whole assembly on the bench - IMHO its the only way to get good clear access to tighten up the filter connections. Only additional work is the R&R of the pump power leads and loosening the 4 rubber mounted bolts.
jp 83 Euro S AT 54k

 

what jp said.

its far easier to get at the pump, copper washers, the metal fuel line, the filter, the check valve etc when its all on the bench.

Given theres all ready fuel present remember to disconect the battery before releasing the pump power leads.

 

Wow, Brad. Sorry about the pump; sitting around for 8 years probably didn’t help... On the heels of MrMerlin, you were able to pressurize the system the other day and then you were going to clean off the top of the tank. Is it possible there's a kink in the return line up there? Regardless, it's great soontobered84 is sending you another pump—one way or another this community will get that car running! And since the pump didn't work, it looks like I now owe you a beer.

 

As long as the beer keeps flowing all is good !

 

I will try this for sure tonight. I may disconnect the test valve on the passenger head and blow into the line on the top of the tank. Fuel should flow out here. So that line is the return fuel line? I was wondering where that line went into the tank.

Thanks for the advice.

I got your PMs. Dang guys, the outpouring of support from this community is crazy! I love it. I'm hoping this works and I can drive her down saturday! =)

I put the pump in while everything was in the car, but when taking everything apart to inspect and double check everything I found that taking the whole thing out was much easier. And will continue to remove it this way.

No worries. I thank you for sending it anyways. I just hope it isn't a clogged system that ruined the pump. Going to test it tonight. Just wish I had compressed air to use.

AMEN!

 

Well I went out to check for clogged lines on my lunch break and this is what I found.

I was able to blow through all the lines in my system with just my lung pressure. So no lines are clogged. However, I cannot blow through the fuel level sender.... I took it out before and this 'drip' wasn't there. I took the nut off the bottom of the sender and this is what I found under the plastic.........

So the fuel pump did fail, but I am going to say that the pump was a good pump and it was this that made it fail. I wonder how much pressure built up before it gave out.....

Looks like it is time for a new fuel level sender. Anybody got one? I called one of my local 928 guys and he may have one. I will be verifying this tonight, but if he does not I will be needing one.

I currently have this soaking in mineral spirits just to see if it will break this stuff down. But I really have no hopes of salvaging this sender.

 

What is that stuff? Looks like tar.