1G FWD fuel pump problems

['89beretta]

While trying to install a new Walboro 190 in my 91 GS-T, I've managed to damage the fuel line coming off of the assembly. I couldn't get the bolts off because everything is rusted (this isn't your normal rust, this is "15 Wisconsin Winters" rust). These bolts haven't seen a wrench since the assembly line and I don't think they're planning on going anywhere. The metal seems very weak and britol and I don't want to risk messing anything else up.

What are my options? Find a used, unrusted assembly and do anything to get the old one off, or is there a way to patch the damaged fuel line?

 

[BaddAssGst]

If your talking about the 6 or 7 screws that hold the rusted part to the tank.. Grab a set of vice-grip pliers and clamp them on the screws and turn them to get them out. I had to do the same thing but when I put everything back together, I used tiny bolts and a lock washer, just in case.

 

[steve]

Lots of PB Blaster on the nuts. Clean up as much of the rust as you can from the threads before you start putting any torque on them. Once you start try working them back and forth to break up the rust from the threads until you get them off. Replacing the tank studs is no fun.

I replaced my pump assembly with a rust free one sourced from outside the rust belt. People have used fuel line double clamped over the hard line but I didn't want any possible fuel leaks. Clamping to rusted lines is hit or miss and it's not a location your likely to inspect often to check for leaks once it's in.

Steve

 

[DSMcamaro]

vice-grip pliers

thats what i used. i live in Wisconsin aswell and my screws were basically too rusty to even get the screwdriver in them. i used a vise grip to break them all loose and the just turned then out the rest of the way with a regular pliers.

Im still trying to find a new tank though cause my old one leaks

 

['89beretta]

Thanks for the advice guys. Yeah, they've rusted so bad that I can't get the screwdriver in them. I've decided to go ahead and find a new assembly without as much damage. I don't want to risk riding around with a cracked little hole in the line coming off of the assembly.

I usually don't look under the car too much. There is rust everywhere. You guys in fair weather climates have it easy.

 

[tfoti]

What do you do when in the process of getting the sending unit lines off, the line above the sending unit cover breaks off because of rust? Thats what happened to me, just wondering of any suggestions on what to do to fix it before buying another one.

 

[NOSLO2PT0]

Lots of PB Blaster on the nuts.

I tried that once. All I got was some chafing and some funny looking bumps on my nuts for a few weeks.

Replacing the tank studs is no fun.

Sure it is. Screw replacing them. Just drill em out and put some self-tapping sheet metal bolts/screws in.

 

[habitatguy187]

I tried that once. All I got was some chafing and some funny looking bumps on my nuts for a few weeks.

Had to revive this, it's just too funny.

 

[steve]

Mike has some strange habits.

 

[timloomis]

My fuel line rusted and broke right at the unit too. I had a spare that someone fixed. They took a firewall fitting and completely removed the old line from the pump. They put the fitting where the line used to be, used some fuel line to the pump, and some brake line to connect to the stock fuel feed line to the filter.