Fuel line doesn't fit new fuel pump

[That Camper Smell]

Hi

First time asking a question and I hope someone can help, just fitted a new fuel pump to our 1983 1.9 watercooled camper, but the fuel line from the tank is too narrow to fit over the end of the fuel pump pipe, do we need to fit a new fuel line down to the tank or have we been sent the wrong part? We have checked the box/invoice against the catalogue and it seems to be the correct one for our year.

Any help is much appreciated.

Thanks

Emma

[Bowton Lad]

Hi Emma, welcome to the forum.

There are a few different sizes of fuel hose but I think the correct one for the pump on a 1.9DG engine would be 6mm. I thought the inlet/outlet pipes on fuel pumps were a standard size. Replacement fuel pumps were usually ie. Pierburg (OEM) but places like GSF & JK seem to have been selling a different make for the last couple of years.

It wouldn't be a bad idea to replace the fuel hose from the tank > inline fuel filter > fuel pump just for peace of mind.

[kevtherev]

tried the washing up liquid on the pump pipe trick with a nice warm fuel line end?

It's not a big job replacing the line..and it's readily available from most motor factors, I guess it might need replacing any way

[That Camper Smell]

Thank you for responding, the fuel pump pipe is noticeably bigger on the new one when compared to the old one. We will have to measure the diameter of our current fuel line and replace it. It is frustrating cos you think it is going to be a small job and then you find something else!! Just want to hear her start up again!

Ta muchly.

[batmangb]

Hi and welcome!
Is the pump from GSF? I had exactly the same thing with a GSF pump a few months ago, the inlet pipe on the pump was much bigger than the existing fuel line. I managed to squeeze it on temporarily but I eventually bought a new pump from Brickwerks with was far superior and fit no problems.

Good luck

Ben

[toomanytoys]

The GSF ones are usually have the connections in the wrong place too, it points at the breather tower..

You shouldnt need to replace all the way to the tank, there should be a small diameter plastic fuel line that never seems to deteriorate.. IIRC the normal fuel line is 5.6mm.. 6mm or 1/4" is too big and loose.. (for carb engined vehicles, fuel injecteds have slightly bigger fuel lines, ) the short bit from the tank to fuel fiter is 7mm..

Dont use "jubilee" hose clips.. use the correct fuel line hose clamps any descent aoutmotive supplier will have 5.6mm and the correct hose clamps in stock..

Hot cup of water to soften the end of the hose hels a lot.. but its less than ideal forcing the hose onto the bigger connector.. poss to use an adapter if you can find one.. step down from the larger hose on the pump to the correct size for the fuel line..

[croc]

Just had a similar problem of the new pump which suits 7.5/8.0 mm ID tube.
Solved by changing the entire fuel line from (new) filter to pump.
5/16 (8.0mm) proper fuel hose from motor factors - 1 metre.
8mm OD hard nylon tube from hydraulics/ hoses suppliers - 3 metre about £2 - more than enough.
Fuel filter has stepped tails to suit both hoses sizes.
Cut short 100mm length off the one metre hose to join filter to hard nylon.
Remainder of rubber hose to connect hard nylon to pump. Make the join well ahead of the engine bay, ie not above the hot engine parts.
Note comments to use proper fuel line hose clips.
Job took about 1/2 hour.

[That Camper Smell]

Thanks for all the responses, the pump is from JK, we will replace the fuel line from filter to pump at the weekend and fingers crossed she will be running again! We will definately consider Brickwerks for parts in future though.

Emma