MFranke

I finally got around to addressing my noisy fuel pump on my '88.

Before I removed the old pump assembly, I noted two issues that most likely were amplifying the noise.

In the first picture, center - bottom, the pump strap worm screw had migrated forward and was no doubt in contact with the metal cover plate.

In the second picture, you can see the metal fuel line from the pump to the filter runs behind the bracket. This line was in contact with the back of the tank. For the new pump assembly, I bent the bracket slightly to give it more "v" and give the metal line some room between it and the tank. I also placed a strip of black foam weatherstripping on the tank where the line runs for good measure.

Both of these issues surely amplified the noise of an aging pump.

I took the whole bracket out. I needed an impact wrench to loosen the bango bolt nut (lower right of second pic), and lots of hot/cold treatments to some of the other joints before I could break them. When I removed the old pump (over 20 years old), I shook it and it had a rattle inside like something was loose.

I put the new pump and filter in and noticed I had not ordered new copper crush rings for the banjo bolt. I tried the old ones, but they leaked. None of the local Autozones etc. carried washers anything close to that size. I annealed the old crush washers by getting them red hot with a torch, and then let them cool a few minutes before sanding them flat. Worked!

The new pump makes a slight noise compared to the old one, which was rather loud, but the whole assembly is nice and quiet now - huge difference!

SeanR

Sounds like you did good. It's a 50/50 shot whether or not you can re-use that metal cross pipe, I always keep an extra one around just in case it bends when removing part.

dzaprev

Where did you get the metal cross pipes?

Chalkboss

I got my (used) metal pipe crossover from 928 Intl. I was ham-fisted when taking it apart and twisted it. You have to exercise caution, it bends quite easily and if it does it will leak.

GregBBRD

Here's what I finally decided regarding that metal pipe....20 years ago....and still practice, to this day:

Never attempt to change a fuel filter unless you have a spare (new) metal pipe....unless you have the time, the patience, and the ability to deal with the leaking fuel while you wait for one to come on UPS.

MFranke

The risk to the pipe would be a lot less if there was a better way to counter hold the banjo bolt. I was successful with careful application of heat and an impact wrench, but this was risky.

I couldn't fit a wrench in there between the motor electric pole towers to counter hold. Does anyone have a solution for this?

Herman K

Annealing - After you get them red hot don't wait drop them in a bucket of cold water use pliers to remove the copper from the bucket of water once it returns to its original color. The copper is now annealed and will be soft and malleable for working - No need for sanding

Brent

I think I've seen this done a few times.

the flyin' scotsman

wasnt there a bbq involved Brent?

Bilal928S4

What about annealing the newer aluminum?? washers?

AirtekHVAC

I had to reuse all the washers on my CIS FD, they had been in there from birth....I just sanded each side until shiny...not a single one leaked....got lucky i guess....went ahead and ordered all new anyway! (Thanks Roger)

mj1pate

Removing the screw-on plug at the end of the banjo bolt is actually pretty straight-forward, if you're discarding the old fuel pump. I just had to think about it a bit (today). I used electrical cutters and cut away some of the plastic shields around the electrical terminals beside the the banjo fitting. Once the plastic is mostly removed, I used a (17 mm I believe) open end wrench on the nut underneath the banjo fitting and the screw-on plug. Securing that nut, while applying torque to remove the screw-on nut prevented the metal line from experiencing any stress. This worked quite well.

Now the challenge comes in when you need to properly tighten the screw-on plug, so as to secure the banjo fitting. Obviously you can't mutilate the new pump in the fashion that I did to the old pump. I suspect that I may have to grind down a wrench, so that it will fit on the nut, in between the electrical terminals so that I can tighten the screw-on plug securely (tomorrow).