5KTQ fuel pump?--R&R

E. Roy Wendell IV erwendell at mac.com
Sat Apr 29 14:31:14 EDT 2006

> I managed to remove the retaining ring and with lots
> of patience and a couple of different sizes screw
> drivers, also removed the breather line (?) as well as
> the return line. I assume the return line is the other
> fuel line that runs to the bottom of the fuel tank?
> The 17mm bolt holding in the main fuel line was easy.
> I pulled the plastic assembly out as much as the lines
> would allow.
> To my negative surprise, I found the hose clamps,
> which attach the fuel lines under the plastic
> aparatus, rusting out. Needless to say, I will be
> replacing those clamps.
> Now, to separate the plastic apparatus from the fuel
> hoses, you remove the rusty (in this case) clamps and
> pull the hose lines off their respective nipples, easy
> enough...not so fast. These rubber fuel lines appear
> original, and, thus look and feel as if they're welded
> to the nipples, one plastic and one metal, also with a
> bit of rust. I know I should replace but for now It
> will have to do until I get my hands on another set.
> Again, so far its been a happy marriage and I'll like
> to keep it that way....bottom line I'm affraid of
> breaking the nipples as I try to pull the hoses apart.
> I want to unplug the fuel lines where they end, or
> begin, depending how you look at it.
> I know one connects to fuel pump.
> Where does the return fuel line attach inside the
> tank?
> The new fuel pump should arrive this afternoon.
> I'm looking to finish the job Friday.
> Depending on time, I might head out to the boneyard
> and search for a plastic apparatus containing the fuel
> sending to compare vs the one in my car and if in
> better shape than mine snatch it.
> Is that plastic apparatus in our 5KTQ same as non Q
> non T? Would the 200s or 100s, newer model year as you
> know, carry the same?

There are apparently some differences between the 200 and 5k cars  
with respect to how the hoses connect to the plastic bottom side of  
the plastic tank header. The high pressure supply line from pump to  
header on the 200 is nylon plastic and attaches to the header fitting  
via a steel flared fitting and nut. You say yours is a rubber hose  
that attaches with a clamp.

I don't know if the quattro shares the same sender unit/header as the  
non-quattro. The tanks are completely different shapes due to the  
requirement that the quattro version fit around the rear suspension  
and differential. I can see that the quattro version would work in  
the non-quattro so my gut instinct would be that they used the same  
part for economic reasons.

The plastic hose nipple for the return line isn't as fragile as you  
think. It has a steel line running through the center of it. The best  
way to take it loose is to use a pair of slip jaw pliers and try to  
rotate the line on the fitting. Once it's been broken loose in this  
fashion it comes off much easier. Needless to say there is some risk  
that the jaws on the pliers will tear up the hose so some cushioning  
material between the jaws and hose might be necessary. It all depends  
on how much force is required. The return hose does not float around  
loosely in the tank. It runs to a port on the bottom of the plastic  
sump filter that the fuel pump sits in.

I'm no longer certain that any of these tanks were lined, at least  
not with anything besides rust. At some point very soon I'll submit  
my whole saga about how rust clogs the screen on the bottom of the  
Bosh pump and causes fuel starvation. There is already a nylon mesh  
screen built into the sump so I cut the steel screen out of the brand  
new pump when I installed it. Two rounds of attempting to vacuum out  
all of the rust in the tank didn't work.

E. Roy Wendell IV
erwendell at mac.com
Too many type 44 tq
A pair of MR2s

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