2G Fuel Sender Gasket

[TSIdad]

Upgraded to a Walbro pump, and found the original gasket was thrashed. Installed the new gasket, but when I try to turn the fuel sender lock ring, the gasket flattens out and prevents the white plastic ring from engaging the threads (see video).

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This should be stupid easy, but I tried several approaches without success. Any advice?

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[99dsmer4g63]

Looks like your not trying hard enough to be honest haha just kidding. That gasket needs to be going into the tank where the sender is going. Use something small and not sharp and work it down into the tank with the sending unit. It’s just a matter of working the gasket and the sending unit in the tank together. Just be persistent and start on one side and work it around the sending unit and tank. Just be careful not to tear the gasket. I know there isn’t a lot of head room in there and breathing over your fuel tank isn’t that enjoyable.
-Good Luck

Also I’ve never tried it but a little lube on the gasket might help it slide in easier with it being new and all.

 

[TSIdad]

Looks like your not trying hard enough to be honest haha just kidding. That gasket needs to be going into the tank where the sender is going. Use something small and not sharp and work it down into the tank with the sending unit. It’s just a matter of working the gasket and the sending unit in the tank together. Just be persistent and start on one side and work it around the sending unit and tank. Just be careful not to tear the gasket. I know there isn’t a lot of head room in there and breathing over your fuel tank isn’t that enjoyable.
-Good Luck

My major problem is that this 19mm / 14mm hose fitting is either welded, fused, or cross threaded by the previous owner. If I could get this hose out of the way, I could have clear access to the entire circumference of the ring. Unfortunately, I have to have the hose through the ring and it’s all sort of in the way as I’m trying to feed the gasket into the tank. Glad to know that “lip” goes into the tank. I’ll keep trying.

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[99dsmer4g63]

My one 99 is the same way. I left that hose attached at the sending unit and unscrewed the other side down under the car in front of the tank. Definitely adds a little more of a pain trying to remove and install. Seems them being fused together is kinda common. I installed a 255 in my one 99 when I was 17 so I’m confident you’ll get it with a little persistence.
-Good Luck

 

[TSIdad]

My one 99 is the same way. I left that hose attached at the sending unit and unscrewed the other side down under the car in front of the tank. Definitely adds a little more of a pain trying to remove and install. Seems them being fused together is kinda common. I installed a 255 in my one 99 when I was 17 so I’m confident you’ll get it with a little persistence.
-Good Luck

Okay, I took the gasket off the fuel sending unit and mounted it to the tank first, then stuck the sender into the gasket. That worked!! Second question if you don’t mind. We also installed a new FPR. What should the psi be set at on the FPR? Mostly stock setup with a 14b turbo, stock injectors, FMIC, 3” exhaust etc.

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[Dusty Landrum]

1G n/t - 47-50 psi
1G turbo m/t -36 - 38 psi
1G turbo a/t - 41 - 46 psi
2G turbo - 42 - 45 psi
2G spyder - 47 - 50 psi

With vacum line attached:

1G n/t - 38 psi
1G turbo m/t 27 psi
1G turbo a/t 33 psi
2G turbo - 33 psi
2G spyder - 38 psi

 

[99dsmer4g63]

With the vacuum line on mine is about 35 psi. Which is about 43.5 with it off which is what I used when scaling the injectors in link. Looks like you have the exact fpr that I have My car is manual idk if yours is or not. I set my pressure with the vacuum line off btw.
-Daniel

 

[TSIdad]

1G n/t - 47-50 psi
1G turbo m/t -36 - 38 psi
1G turbo a/t - 41 - 46 psi
2G turbo - 42 - 45 psi
2G spyder - 47 - 50 psi

With vacum line attached:

1G n/t - 38 psi
1G turbo m/t 27 psi
1G turbo a/t 33 psi
2G turbo - 33 psi
2G spyder - 38 psi

Great info. Thank you!

With the vacuum line on mine is about 35 psi. Which is about 43.5 with it off which is what I used when scaling the injectors in link. Looks like you have the exact fpr that I have My car is manual idk if yours is or not. I set my pressure with the vacuum line off btw.
-Daniel

Thank you. Yeah, 5 speed manual (95 TSi AWD) I’ll set the psi tomorrow. Then we have to install the new Innovate Motorsports SCG-1 AFR. This is my 19 yr old son’s car so we’re very new to DSM. It’s been a blast of a project, but ready to get it on the road .

 

[We're on Boost]

My major problem is that this 19mm / 14mm hose fitting is either welded, fused, or cross threaded by the previous owner. If I could get this hose out of the way, I could have clear access to the entire circumference of the ring.

The threaded part of that fitting is probably fused together by corrosion. That's how it was on my 1990, way back in 2009 when I wanted to replace my rubber fuel hoses.
I don't know if my solution would help you because the part like a nut with big wrench flats would still be there, but it makes it easy to take the hose off and it gets you a new rubber hose to the stock hard (steel) line that is under the car.

I removed the original rubber hose by cutting through the crimp collar that holds it to the barbed fitting. Used a thin abrasive cut-off wheel in a dremel tool to cut the steel collar being careful to not go too deep. What emerged was a beautiful hose barb perfect for 5/16ths inch ID fuel hose.

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Here's what it looked like at the tank when done. Regular size 13 fuel injection hose clamps clamping it to the barb:

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And here it is under the car done the same way.
I guess you'd have to be sure you can get at both ends with a dremel before even starting this. But it worked great on my 1990.
At the time I used J30R9 hose which was good.
The newer and "better" stuff is 30R14 T2 (Gates 4219BF) which I'm using now in a couple places.
In this pic you can see where I cut into the one wrench flat a little with the dremel.

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[TSIdad]

The threaded part of that fitting is probably fused together by corrosion. That's how it was on my 1990, way back in 2009 when I wanted to replace my rubber fuel hoses.
I don't know if my solution would help you because the part like a nut with big wrench flats would still be there, but it makes it easy to take the hose off and it gets you a new rubber hose to the stock hard (steel) line that is under the car.

I removed the original rubber hose by cutting through the crimp collar that holds it to the barbed fitting. Used a thin abrasive cut-off wheel in a dremel tool to cut the steel collar being careful to not go too deep. What emerged was a beautiful hose barb perfect for 5/16ths inch ID fuel hose.

You must be logged in to view this image or video.

Here's what it looked like at the tank when done. Regular size 13 fuel injection hose clamps clamping it to the barb:

You must be logged in to view this image or video.

And here it was under the car done the same way.
I guess you'd have to be sure you can get at both ends with a dremel before even starting this. But it worked great on my 1990.
At the time I used J30R9 hose which was good.
The newer and "better" stuff is 30R14 T2 (Gates 4219BF) which I'm using now in a couple places.
In this pic you can see where I cut into the one wrench flat a little with the dremel.

You must be logged in to view this image or video.

Brilliant. Great to know for the future. Today it isn’t leaking but you never know what will happen tomorrow . Thanks again!

With the vacuum line on mine is about 35 psi. Which is about 43.5 with it off which is what I used when scaling the injectors in link. Looks like you have the exact fpr that I have My car is manual idk if yours is or not. I set my pressure with the vacuum line off btw.
-Daniel

When you say with the vacuum line off, does that mean with the barb/nipple open, or with the hose off and you covered the barb with your thumb to measure the psi? I’ve seen conflicting things on YouTube.

 

[99dsmer4g63]

I just pull the vacuum hose off of the fpr itself. Then stick my thumb over the hose that I pulled off so the car doesn’t have a vacuum leak while I adjust the pressure to what I want. I have 272 cams so your vacuum reading with the line on may be different than mine as my vacuum is only about half of a stock car while idling.
-Daniel

 

[TSIdad]

I just pull the vacuum hose off of the fpr itself. Then stick my thumb over the hose that I pulled off so the car doesn’t have a vacuum leak while I adjust the pressure to what I want. I have 272 cams so your vacuum reading with the line on may be different than mine as my vacuum is only about half of a stock car while idling.
-Daniel

Got it. That was easier than I thought. We are just newbs. Thanks again!