Plastic fuel reservoir where main fuel pump slips into is cracked at the seam. Four years ago I JB Welded it and it held up. Last year it started dripping again, so I refixed it. And now it's dripping again. I'm done repairing it.
I don't think a new/NOS unit exists on this planet. Lots of used ones, but each can have the brittle plastic/seam split issue eventually. So I see two options: 1) fabricate a new reservoir, with return line nipples, etc.... And use the existing fuel pump. Would have to made out of gasoline safe plastic (not pvc or abs, but rather hdpe or similar), or out of metal (6061 3" diameter aluminum tube with 0.125 thick end plates is about $20 from online metal supply's). 2) scrap the entire assembly, pump, fuel accumulator, etc and go with an aftermarket Walbro-type high pressure in-line pump ($75 or so)... Still retaining the stock lift/transfer pump. Other options might involve junking CIS-E entirely and going megasquirt, carbs, or upgrade to CIS-E motronic, but all of those options are cost prohibitive for this car and my preferences. There are lots and lots of stories of mk2's using mk3's tank and pump (mk3's had 1 main pump in the tank as opposed to mk2's in tank low pressure pump and high pressure main pump).... But these (successful) stories are all in the later mk2's where either digifiant or cis-e motronic is involved (both are lower pressure systems at 40-50psi, whereas plain cis-e needs 80+psi to keep the mechanical injectors open). Research on using an aftermarket in-line high pressure fuel pump with cis-e is mixed...hard to tell if the bad experiences I am reading about are due to the individual not properly plumbing the return lines/excess pressure from transfer pump/etc. I can't believe I am the first person to be in this position on the list... What have others done? Any driveability issues, hot/cold start issues, etc? Thanks!!! Denis -- You received this message because you are subscribed to the Google Groups "MK2-16v" group. To unsubscribe from this group and stop receiving emails from it, send an email to [email protected]. To post to this group, send email to [email protected]. Visit this group at https://groups.google.com/group/mk2-16v. To view this discussion on the web visit https://groups.google.com/d/msgid/mk2-16v/CABdgnr6ifc6y7nayB3%3D8-0KEBrZimadPAU2WhD9RsE-xAP04eg%40mail.gmail.com. For more options, visit https://groups.google.com/d/optout.
