Rusted fuel pump assembly. What caused this?

[m[ohio]]

Ok, so I dropped a Walbro 255HP pump into my 99GSX today and when I pulled the fuel pump assembly out of the tank I noticed it was covered in THICK rust. Everything metal was rust covered including the fuel pump itself. What would cause it to rust like this? And has anyone else ever seen this after taking their pump assembly out? I've changed out at least ten fuel pumps in various DSM's and have never seen one spec of rust on the inside of the tank's fuel pump assembly.

Also, would this affect the grounding of the fuel pump because I'm noticing that my Walbro is a lot louder that all of the other Walbro 255's I have installed. I know the Walbro's are LOUD, but this one is crazy loud... sounds like it's going to give up since it's straining so hard for voltage or something. The car is also bucking under acceleratiion like it's being starved for fuel. Any thoughts?

 

[xcelr8n]

thats very weird man, my 1g, I recently did the fuel pump, and my sending unit was so destroyed I snapped the fuel line in half, and broke 2 studs, but the inside of it was as shiny as day 1...
do you often run very little gas in the car? aside from that i cant think of much that could cause this..

 

[m[ohio]]

Usually fill it up when it gets to about 1/4 tank so it never really sits around with less fuel than that. Always run good Shell 93 or Sunoco 94 gas too.

 

[xcelr8n]

is the tank full of rust etc, or juss the sending unit assembly, Id say buy a new or used assembly in good shape, I wouldnt put a rusty ass unit in my tank.

 

[fooked]

I'd say the noise problem could be a bad ground. Have you checked to make sure the pump is grounded correctly?

 

[Omega]

You have or had water in the tank. Was the car ever flooded?

If I were you, I would replace the whole assy. How was the tank? If you shine a light into there can you see any rust?

 

[m[ohio]]

Doesn't look like the tank itelf is rusted on the inside, just the assembly. The car has never been in a flood or underwater in any way. I wonder if I got a tank full of watered down gas at one point?

 

[drivensolo88]

sorry to revive a really old thread but im trying to install a walboro 255lph in my 1g. The problem is that the 6 bolts that hold the pump assemply down are so rusted i cant get them off. Any suggestions? Also my fuel line also broke when trying to sepearate the fittings due to rust .

 

[crimsondragon]

PB blaster and a breaker bar.