1g AWD fuel pump fustrations

[1bad420a]

Well I have been in the DSM game for 4 years now and picked up a straight,clean 90 AWD . After grabbing a ECU, Battery ,oil, and plugs the fuel pump was apparently bad. Guess what , no surprise here , the darn fitting going to the rubber hose wont break loose! I have tried soaking it in PB blaster, used 19 and 14 mm flare wrenches , and well the nut is toast.
Here is my question I present to you . Can / is there a way to cut the metal line in two and splice it together w/ some type of fitting . Sort of like a compression fitting on a water line ??
Well anyway there is my problem I have run out of ideas and really don't want to go out and buy a new sending unit .
Thanks in advance
And yes i did search w/ no luck the only thing that came close was in the tech articles about replacing the whole line w/ a rubber line to the pump ...

 

[Arod]

I don't know the exact setup of the fuel lines on these cars, but you can cut metal line with a tubing cutter and reflare the end and then use any type of flare fittings to get what you need.

Hope that anwsers your question.

 

[1bad420a]

Here is the assemb. , Taken off VFAQ, and the fitting is rounded off , the metal line is roughly 1/4 in diameter or a bit larger . this is what I am thinking of cutting and repairing .

 

[steve]

Undo the rubber hose under the car where it attaches to the hard line running to the front and pull the whole assembly with the hose out of the car. Then you can put the nut in a vice and turn the hose fitting with a wrench since the nut is fixed and doesn't turn.

Steve

 

[Pure92TSi]

The one under the car isn't any easier to get off. Just take two vice grips lock them down on the both sides of the fitting as hard as you can and hit one with a hammer. It will pop eventually. I did it on accident with mine. I was just so pissed at it that I hit it like that and it popped loose.

 

[steve]

The one under the car isn't any easier to get off.

I haven't found that to be the case but we see a little more corrosion here. The salt spray seem to reach the top of the tank but none of the water that might rinse it off seems to, where the lower fitting gets both. The fact the both the hose and the nut on the lower fitting can turn also seems to help get them apart where on the upper fitting only the hose can turn without damaging the hard line.

Steve

 

[1bad420a]

That sounds like a good Idea I'll try that before I kill the metal line. Thanks and all sugestions are helpful.

 

[92GSXBaltimore]

you could try to undo the lower fitting, remove the whole pump assembly, let it dry and use a torch on the fitting.

 

[1bad420a]

Considering there is only a galon of 100 octane I put in it to see if anything would happen I don't think that a torch on it would ignite the fuel if I did it from the location it is in . Either way thanks for all the help I will let you guys know what worked w/ more pics and if I have to fix the line a tech write up as how I went about fixing it !

 

[steve]

Considering there is only a galon of 100 octane I put in it to see if anything would happen I don't think that a torch on it would ignite the fuel if I did it from the location it is in .

Are you planning on entering the DSMtuners version of the Darwin Awards?

I hope your not saying you have 1 gallon of fuel in a 16 gallon tank that your going to apply a open flame to. It's a little lean for the biggest bang but it's close enough.

Steve

 

[1bad420a]

No not actualy going for the darwin award . I can drain the tank if need be to try this method . I am crazy not stupid. Thanks for the concern

 

[Arod]

An empty tank is more explosive than a full tank!!!! I'd rather be doing that with a full tank than an empty tank, even if you drain the tank there are still very explosive vapors in the tank. You would then want to fill the tank with a harmless vapor, like CO2 or CO or fill it up with water anythin but empty with fuel vapors!!!!!!!!!!!

 

[steve]

^^ Exactly.

Please don't become a statistic.

Steve

 

[1bad420a]

Update!!!!!
I got the Fitting loose ! But As I looked in the tank and at the sender there is no hope for either of them . There is a thick Black melted hershey bar like substance all inside the gas tank and all over the sender unit . Needless to say the tank will have to be cleaned and I am afraid the sender is shot .
Now it is time to make the decision to cut the floor pan to accomidate a fuel cell or find a new tank and sender .

 

[kelvinb]

if you were to heat it up, you can take a hose from the exhaust of a running car, and run it into the tank. no oxygen no fire. just like welding a gas tank.