16v fuel pump complete Wanted

[blackrado1 0]

Has anyone out there got a complete fuel pump with body and fittings for a 16v, 1990 model, mine is leaking slightly from the top of what looks like the fuel return line on a small bung, so require a decent unit to replace unless anyone knows if it can be repaired?. Jim.

[vw rule 19]

Hello there,

 

I did see one on Ebay late last week which was off a early 1.8 16v or 2.0 16v Corrado.

If I can find it again I'll give you the item number.

 

As far as I remember the 1.8 16v and 2.0 16v us the same fuel surge pot,

it's the same as the MK2 Golf but this has the push on fuel hose end tip on the external fuel pump,

where as the Corrado has the male thread connection type I think.

 

 

Hope this helps.

 

Si

[blackrado1 0]

Hello there,

 

I did see one on Ebay late last week which was off a early 1.8 16v or 2.0 16v Corrado.

If I can find it again I'll give you the item number.

 

As far as I remember the 1.8 16v and 2.0 16v us the same fuel surge pot,

it's the same as the MK2 Golf but this has the push on fuel hose end tip on the external fuel pump,

where as the Corrado has the male thread connection type I think.

 

 

Hope this helps.

 

Si

Hi, many thanks for the reply, It does help, cheers, jim.

[vw rule 19]

Hello Jim,

 

I've found the item on Ebay but the guy has already sold it.

The Ebay item number was ( 11 12 35 41 16 90 )

 

I've just found another one off Ebay but it's off the MK2 Golf,

so it might fit your Corrado but really depends on what size the fuel pump housing is.

The Ebay item number is ( 26 13 49 66 61 52 )

 

The OEM part numbers for these fuel surge tanks are, I think.

Part N.o: (535 201 043) for Corrado 1.8 16v eng code(KR) and 2.0 16v eng code(9A)

Part N.o: (535 201 043) for later MK2 Golf 16v eng code(KR)

Part N.o: (191 201 042A) for MK2 Golf 8v GTI and early 16V GTI / eng codes RD, GX = 8v and PL = 16v

 

These have the fuel pipes that connect via banjo bolts to fuel filter,

plus have the threaded end on the external high pressure fuel pump.

 

Corrado 16v's 1989 onwards.

Part N.o: (191 201 373) Fuel feed pipe from external fuel pump to accumulator.

Part N.o: (505 201 218A) Fuel feed pipe from accumulator to fuel filter.

 

MK2 Golf 1986 onwards.

Part N.o: (191 201 373) Fuel feed pipe from external fuel pump to accumulator.

Part N.o: (191 201 218) Fuel feed pipe from accumulator to fuel filter.

 

Then on other fuel surge tanks like on the MK2 Golf 8v GTI they don't use the fuel pipes above,

they just use some fuel hose as the external fuel pump doesn't have a threaded end.

 

I've sent an email to VW Classic Parts in Germany just to see if they have got any,

of the plastic fuel surge tanks for the 16v Corrado's.

Looks like there are a few different types as some of the fuel pumps are different,

sizes are 46.5mm / 52mm and 60mm,

so you need the right size fuel pump to fit the correct surge tank unit.

 

Hopefully I'll hear something back after Christmas.

 

 

The only other thing to do is to have one made out of alloy,

loads of fuel surge tanks from 1.5 ltrs to 4 ltrs are on Ebay,

so us that have the 16 valvers might have to purchase a alloy surge tank,

and fabricate it fever to hold the original 52mm or 60mm high pressure fuel pump,

I've already thought about doing this.

Or it's to do away with the under car external fuel pump,

and fit a high pressure fuel pump complete with surge pot base into the main fuel tank.

 

 

Hope this helps.

 

Si

[vw rule 19]

Don't know why there's a face on the post I just put up :shrug:

 

MK2 Golf 1986 onwards.

Part N.o: 191 201 373 Fuel feed pipe from external fuel pump to accumulator.

 

Part N.o: 191 201 218 Fuel feed pipe from accumulator to fuel filter.

 

Hopefully this one is ok :lol:

 

Si

[vw rule 19]

Just looking in to the fabrication of or purchasing a alloy fuel surge tank,

one to replace on the 2.0 16v Corrado.

The original surge tank is made of plastic which over time leaks,

and of course you can no longer purchase the original one anymore.

I've been in contact with VW Classic Parts in Germany,

who have said they no longer make / supply this part.

 

So for this reason as mentioned above I've been looking in to a close OEM look if poss.

What I've found is a alloy fuel surge tank and 040 or 044 fuel pump.

 

Pump pressure is around 5 Bar (72.5 PSI)

Hose connection 12mm

Fuel Capacity BIS 228 I/h

 

Original fuel pump is 60mm for 2.0 16v Corrado and the pressure is around 5 to 6 Bar, I think ??

So isn't that far off from the 044 pump

 

Also found a alloy fuel surge tank sold by a company called (Etech tuning .com)

Cost is £146.30 with out the pump.

But complete with the 044 fuel pump cost is £286.51

It's fuel holding capacity is 2.3 ltrs

It's 7.25" long

It's 6" wide and then 8.9" wide from the mounting tap arms.

And 4" deep.

Weight is 5 lbs or (2.26 KG)

 

This would be an ideal replacement to the original old plastic one that we all have fitted ,

partly because I've seen a few photo's of one fitted to a Corrado VR6 or G60,

I think it was KEV that sold one on here he had some time ago and attached some photo's.

 

Here's the link of the alloy fuel surge tank.

http://www.etektuning.com/integrated-engineering-billet-surge-tank-submerged-044-pump/

 

This new fuel surge tank it states it has a treated interior,

a special anodizing lining process that protects the inner alloy from strong fuels,

which of course over time can eat through plastic or weaken alloy,

so the treated inner lining should last a fair few years hopefully.

Might even be able to fit the VW original type fuel pump into this alloy surge tank,

once the black plastic triangle retaining adaptor has been removed off the pump.

 

I've still got my original plastic fuel surge tank fitted to my Corrado,

which is going to be 20 years old later on this year,

so it's really only a matter of time until mine will start leaking,

plus it's still got both original fuel pumps fitted.

So I'd rather try and source a good replacement now.

 

The only other thing I've thought about is to have a fuel surge tank fabricated up,

same spec as the OEM plastic ones but made out of alloy,

this way should be able to still use the original fuel pump.

 

I did find a company in the USA that were selling the OEM plastic fuel surge tanks,

for the MK2 Golfs / Jetta's and the Corrado 1.8 16v / 2.0 16v / G60

But they've sold out of all sizes 46.5mm / 52mm / 60mm

and are not restocking the part so looks like a lot of people are going to be having the same issue.

I did mention to VW Classic Parts that people are screaming out for these fuel surge tanks,

but like I say they're not going to remake / re-supply them.

 

I can't find anyone in the UK who will supply the OEM plastic surge tank.

 

 

Si

[vw rule 19]

Right this is another USA company that I've just found,

they are called Redline Motive.com,

and they do ship goods world wide.

 

I'll see what I can find out.

 

Looks like they do the full rage for the MK2 Golf / Jetta / Passat and Corrado,

for the OEM black plastic fuel surge tanks.

http://www.redlinemotive.com/replacement/volkswagen/fuelpumphousing.asp

 

This is the link that shows they don't stock it at the moment.

http://www.redlinemotive.com/store/replacement/wizard.asp?year=1993&make=VW&model=PAS--001&category=E&part=Fuel+Pump+Housing

 

 

Si

[vw rule 19]

This is the company that I was looking at originally,

but they don't ship goods out side of the USA,

and aren't really looking at restocking this item.

http://www.partsplaceinc.com/products/product-detail.aspx?sku=9579

 

 

So like I say I'll do some digging around and see what I can find out,

about this other company above i.e Redline Motive.com

 

 

Cheers.

 

Si

[blackrado1 0]

The information you have posted is awesome Si, thank you very much for all your in put on this matter, I will keep trying to get a solution but your help has been fantastic and once again thanks.

[vw rule 19]

Right just a quick update,

 

I've had an email from the USA company called Redlinemotive.com,

only just noticed it as it was in my junk mail.

 

They are looking into my enquiry for the plastic fuel surge tank,

for the 4 cyl Corrado's so hopefully they'll come back with good news.

 

If not then I think I'll be fabricating my own out of alloy,

or might have to purchase that alloy one from that other company in the USA,

that's going for around £286.51 complete with new fuel pump.

 

Will just have to see which way is the most cost effective and most practical.

 

 

Si

[Rorgasm 10]

Good work Si:thumbleft:.

 

It's only a matter of time before I need to address my 20year old fuel pump. Had an advisory on the MOT as the pipes aren't looking that clever & chances are as soon as I start playing around with it, it'll stop working (always the way).

 

Rory

[Dubster101 10]

Hi I'm new to this so apologies if I've jumped into an old thread. Can I ask if you managed to find a solution to this predicament that seems to becoming very common? I need help on this subject as my 2nd fuel housing has developed a leak (after only 14 years on the car too!) Did the solution from Etektuning work out? I'm thinking of having a bespoke housing made in stainless steel if I can't buy one.

 

Many thanks,

[vw rule 19]

Hello there,

 

I've been too busy unfortunately over the last 18 months, to go any further with the company Etektuning regarding their surge tank & 044 pump set up.

I haven't been on this forum for ages now due to other commitments, I'm just starting to get time back to myself, to get back on with my Corrado, which has been off the road now since early / mid part of 2015.

 

I managed to get hold of a decent secondhand original Corrado 16v fuel surge tank, as a spare plus also to take measurements from, as I intended to get it copied close to OEM as possible,

I was looking at 3D printing or fabrication firms.

But like I say just haven't had the time lately

I will get back on this as it's an issue that needs a solution, sooner rather then later.

 

Si

[vw rule 19]

Right it's been a while now since I was last working on this fuel swirl pot issue,

due to work and no spare time to take it any further.

 

I've got some spare time again now coming up,

so will be getting back on track with this.

 

Update

I've been in touch with various fabrication companies close to me near Bournemouth,

1) one can reproduce the fuel pipes that go from the fuel pump to accumulator and from the accumulator to fuel filter.

They just want me to take a set in so they can see them in the flesh to copy them.

 

2) I'm also looking at getting the original swirl pot face flange made, basically this is where the original fuel pump with syphon fit into. Once made this can be welded into a alloy swirl pot which would still allow you to fit and bolt in the original Bosch fuel pump with the triple / triangular plastic retaining clamp. Again they want to see the original swirl pot and original fuel pump so they can scan / copy it.

 

3) plus one of my old customers is a industrial fabricator, he makes coolers and fuel burners, so if I have a word with him he could possibly copy the original swirl pot, but leave the front face open to weld in the fabricated face flange, to still be able to use original pump set up.

 

 

Does anyone else need a swirl pot sorting out soon for their Corrado 16v ??

 

 

I'm going to see these companies in person on Monday 25th June 2018

 

 

Si

[vw rule 19]

Below are the part numbers for the original set up, just in case any of you are still able to reuse your old original swirl pot.

 

 

535 201 043 = Plastic fuel swirl pot for 9A & KR engines (is still obsolete)

 

191201505A = Fuel swirl pot mounting bracket ( obsolete no longer available )

 

191201274 = Rubber mount buffer (still available through Heritage)

4 needed they attach to above bracket.

 

191201280A = safety speed nut (still available) 4 needed they attach to above rubber mounts.

If the 4 retaining hex nuts are loose then these safety speed nuts keep the swirl pot bracket held up.

(Obsolete at VW)

But showing in stock with a company called NKAutomotive on Ebay,

their part n.o: WHT002257

 

 

191 201 373 = Fuel feed pipe from external fuel pump to accumulator.

(Possibly still available)

 

505 201 218A Fuel feed pipe from accumulator to fuel filter.

(looks like this is obsolete now)

 

 

Hope this helps

 

Si

Edited June 16, 2018 by vw rule

[vw rule 19]

I've managed to drop down the whole fuel pump unit in one piece, and got it all stripped a part. My original plastic swirl pot doesn't look too bad, unfortunately the 4 fixing points where the anti vibration mounts fix to are brittle / weak, I've luckily got a spare swirl pot. But like I say I'm looking into getting some of these items refabricated.

 

I've taken a fair few photos but can't post them up on here, I could last year but for some reason they don't upload on this Forum now.

 

 

Si

Edited June 16, 2018 by vw rule

[vw rule 19]

Update

 

Right it's good news so far,

the fabrication guy I know said if he was to copy my old swirl pot set up from scratch,

it would be around the £600 mark, but he told me if I got hold of a new after market swirl pot, he could cut it down or weld brackets on, plus has access to a full precision engineering workshop, so he might be able to do it for £250 or £350.

Basically after my discussion with him on Monday 25th June, I purchased a alloy swirl pot for £41 off Ebay, it's (150mm x 150mm) equal square complete with a fitting flange to hold a 044 Bosch fuel pump.

I believe the capacity of this new swirl pot is 2 litres at the moment,

 

Anyway this new after market unit arrived on Thursday 28th June, I spent most of Thursday and the morning of Friday taking measurements of my original old unit and the under side of my Corrado and the new universal unit.

With all the info on paper and the items in question, I've given it all to him to look at,

so he's starting on this hopefully on Monday 1st July.

 

Si

Edited July 1, 2018 by vw rule

[vw rule 19]

OLD UNIT

 

the original swirl pot is made of a treated plastic that over time becomes brittle or the unit can leak from the main joining seam,

or from the two return connections on the top, again which are made of plastic.

 

Measurements off old unit:

 

Height from base to top of return connectors 140mm

 

Height from base to top of unit 125mm

 

Original fuel pump (61mm diameter)

12mm Banjo outlet complete with one way valve.

When fitted the unit with pump faces towards back of car.

 

Fuel feed to swirl pot this has a one way valve inside also.

Return connectors on top usually have arrows showing direction of fuel flow.

Arrow into unit is fitted with a one way valve (return from injectors) pressure is obtained by fuel pressure regulator.

Arrow out of unit return back to main fuel tank.

 

 

Old unit also has attached plastic clamp to hold fuel accumulator.

Accumulator front face where fuel pipes attach, 55mm in diameter

thinner back face 42mm diameter.

Also there's a spacer plastic sleeve that fits over the back thinner part of accumulator,

52mm diameter x 2mm

 

Fuel Accumulator

inlet M16 x 1.5mm male thread

outlet M14 x 1.5mm male thread

 

*******************

 

Original fuel filter

inlet M14 x 1.5 female thread for (Banjo)

outlet M12 x 1.5mm female thread for (Banjo)

 

***************

 

Attached to all 4 corners at the top of swirl pot are 4 anti vibration rubber mounts.

VW n.o: 191 201 256

 

Measurements:

Rubber diameter 15mm

Length of protruding stud 10mm

Stud size 6mm

Over all length 135mm

Edited July 1, 2018 by vw rule

[vw rule 19]

BRACE CRADLE BRACKET

 

191201505A

Fuel swirl pot cradle brace bracket

(obsolete no longer available)

 

This large bracket is bolted to under side of Corrado, on drivers side RHD under rear seat area. This cradle bracket holds the original fuel swirl pot set up, the front of bracket holds the fuel filter on the 16v Corrado's.

 

 

4 studs fixed to underside of car.

8mm diameter.

 

Distance between 8mm studs:

This is not a equal Rectangle it's slightly off set.

 

Between front studs 95mm

 

Between rear studs 83mm

 

Between front to rear studs outer side 179mm (close to drivers door)

 

Between front to rear studs inner side 193mm (next to centre silencer heat shield)

Edited July 1, 2018 by vw rule

[vw rule 19]

NEW UNIVERSAL SWIRL POT

 

This is like I say (150mm X 150mm) equal square

it has a fitting flange to hold a 044 Bosch fuel pump, also swirl pot has 3 AN6 inlets for fuel feed and returns.

 

AN6 screwed fitting these are welded into place, and you simply purchase AN6 adapters that will screw in.

 

AN6 = parallel thread with O-ring seal attached to which ever adapter you want to use.

 

AN6 = OD 3/8" (9.52mm) / ID 0.297" (7.54mm)

 

So I'm basically going to get this universal alloy swirl pot cut down a bit, from 150mm down to 110mm which would mean I'll lose where the AN6 inlets are now, so I'll have these welded into similar places as the original set up, so bottom right will be fuel feed in from main fuel tank, I'll have to plumb in a one way valve for that new fuel feed.

Then the two returns on top again similar places as the original,

also will have to plumb in here a one way valve on return from injectors, but return from swirl pot to main tank I shouldn't have to.

 

Also original fuel pump is 61mm diameter.

044 Bosch fuel pump is 60mm diameter.

 

So will have to see as regards cost if I'll use the new 044 Bosch pump, or get the fitting flange adapted to hold the original pump complete with original syphon filter ?

 

044 Bosch pump

Inlet M18 x 1.5 female thread

Outlet M12 x 1.5mm thread (Banjo)

 

Might also get a new cradle brace bracket made out of alloy, will have to see how he gets on adapting the alloy swirl pot.

 

Si

Edited August 18, 2018 by vw rule

[vw rule 19]

Ebay items:

 

After market one way valves, push on type 6mm and 8mm available.

https://www.ebay.co.uk/itm/Sytec-Motorsport-One-Way-Valves-For-Fuel-In-Silver-480-Ltr-Hr-Flow-Rate/371053282523?hash=item56647fc4db:m:mnBdalXdwbMWxmWayb_0vUg

 

 

This is the type of fuel swirl pot I've gone for,

which is going to be cut down and modified.

https://www.ebay.co.uk/itm/New-2L-Billet-High-Flow-Swirl-Fuel-Surge-Pot-Tank-AN6-for-044-External-Fuel-Pump/202095069403?epid=13004294398&hash=item2f0dce08db:g:~VMAAOSwRQxaUxvD

 

 

Si

Edited July 1, 2018 by vw rule

[vw rule 19]

Link below is for the fuel feed pipe from main fuel pump to accumulator,

cost is £36 (part number 191 201 373)

Showing in stock.

 

http://www.veedubmachine.co.uk/fuel-supply-pipe-accumulator-to-fuel-filter-vw-golf-jetta-mk2-k-jetronic-191201326.html

 

 

Si

[vw rule 19]

Right I've got some good news.

 

I met up with the fabricator early doors this morning, as he wanted to see what I thought about what he'd done so far, with adapting the new alloy swirl pot close to the original plastic one as possible.

Basically it looks mint he's cut away the bottom section just as I wanted,

so originally it was 150mm X 150mm but it's been cut down by 40mm.

The new measurements are now 150mm X 110mm

The length and width are the same as 150mm only the height has been reduced down by 40mm to make it 110mm.

 

This had to be done in my opinion because it was too deep before and also repositioned the inlet ports. Plus he's made / welded on a new bracket for the fuel accumulator very similar to the original set up.

 

He charged me £230 for adapting my new alloy swirl pot, plus he modified the metal cradle bracket so I'll still be able to use it.

I've just got to fit it and check everything is lined up ok, then I can replace the rear fuel pipes / hoses, and then get the fuel tank fitted back in.

 

Like I say I've just got to check fitment,

just to be sure nothing needs adjusting,

but I think it'll be ok ?

 

The fuel pump I'll be using is the Bosch 044 fuel pump £100 to £160 max for genuine Bosch,

or £38 to £65 for 044 none genuine Bosch.

 

4 new spacer sleeves 191 201 278A

 

4 new Rubber mount buffers 191 201 274

 

4 new safety speed nuts 191 201 280A

 

New alloy universal fuel swirl pot £41

But it needs fabricating.

 

Fabrication of above swirl pot £230

 

So looks like the full spend so far will be around the £500 mark.

But just got to replace the rear fuel pipes / hoses, and sort out some AN6 fuel fixings to attach to new modified swirl pot.

 

So realistically I'd say £600 would cover your costs if any of you want to sort out your old warn fuel swirl pots on your 16v Corrado's.

 

Si

Edited September 23, 2018 by vw rule

[vw rule 19]

I've got all my notes / drawings / measurements of the old set up and the new set up.

Plus I've left a copy of all my notes with the fabricator I know, just in case anything still needs changing / adjusting on my new fuel swirl pot, or if anyone else wants one doing in the future.

 

Si

[Bauhaus 3]

Are you trying to achieve something like this which all mounts under the car on the 4 studs in the oem position ?