Fuel Pump Install - HELP!!!
Thread Starter
Drifting
Joined: Oct 2006
Posts: 1,724
Likes: 23
From: Minnesota
Fuel Pump Install - HELP!!!
'98 A4
I'm having major difficulties installing my new LPE fuel pump. Removing the old one and attaching the new canister was quite simple (although I managed to break the crimp clamp that came with it). The problem I'm having is actually inserting the pump assembly into the tank. I've had it in and out several times (I've got that down to a science now). The problem is that the pump assembly lid will not sit flush against the tank. No matter what I try one side of the lid sticks out about 1/4". The fuel level indicator arm swings freely as it should. It feels like it is butting up against something so its not like the sock could be bunched up or anything. I've verified that the new canister is exactly the same size as the old one.
I'm at wits end on this, any advice would be greatly appreciated.
Has anyone run into this issue or have any idea what the pump assembly could be binding on?
I'm having major difficulties installing my new LPE fuel pump. Removing the old one and attaching the new canister was quite simple (although I managed to break the crimp clamp that came with it). The problem I'm having is actually inserting the pump assembly into the tank. I've had it in and out several times (I've got that down to a science now). The problem is that the pump assembly lid will not sit flush against the tank. No matter what I try one side of the lid sticks out about 1/4". The fuel level indicator arm swings freely as it should. It feels like it is butting up against something so its not like the sock could be bunched up or anything. I've verified that the new canister is exactly the same size as the old one.
I'm at wits end on this, any advice would be greatly appreciated.
Has anyone run into this issue or have any idea what the pump assembly could be binding on?
Thread Starter
Drifting
Joined: Oct 2006
Posts: 1,724
Likes: 23
From: Minnesota
One concern I have is making sure that the fuel sock in placed correctly. Without dropping the fuel cell or dropping the rear cradle the only way to get the pump assembly in is to rotate it 180 degrees. In addition, the fuel sock needs to be inserted first, which requires it to be folded up. I'm not convinced its unfolding correctly in the tank. I would like to add that regardless of how I have the fuel sock inserted, this is definitely not the issue I am having. The fuel assembly is, without a shadow of a doubt, binding on something solid.
BTW, although I've mentioned that the fuel level arm is not in the way (it moves freely as it should), I tried installing the pump assembly without it. Same exact problem. No matter how I rotate it, no matter how I place it, it will not sit flush against the fuel cell. Even if I used gorilla strength, it will not sit flush against the fuel cell.
Is it smart to reuse the rubber seal and bolts?
BTW, although I've mentioned that the fuel level arm is not in the way (it moves freely as it should), I tried installing the pump assembly without it. Same exact problem. No matter how I rotate it, no matter how I place it, it will not sit flush against the fuel cell. Even if I used gorilla strength, it will not sit flush against the fuel cell.
Is it smart to reuse the rubber seal and bolts?
Last edited by reactor2; Aug 19, 2011 at 12:32 AM.
Thread Starter
Drifting
Joined: Oct 2006
Posts: 1,724
Likes: 23
From: Minnesota
Could someone do me a huge favor and post a video of the fuel pump assembly install, just in case I'm missing something obvious. I've read all the instructions A&A, Lingenfelter, etc. They all just breeze over the installation of the assembly back into the cell, which makes me believe it should be really easy. I must be missing something.
Preferably for a '98.
Preferably for a '98.
Thread Starter
Drifting
Joined: Oct 2006
Posts: 1,724
Likes: 23
From: Minnesota
Any change you guys at A&A could shoot a video of how you position the pump assembly in the cell? You must do it several times a week, just have someone stand over your shoulder with an iPhone. 
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I had to manipulate mine a bit to get it in there but it will go in..
Thread Starter
Drifting
Joined: Oct 2006
Posts: 1,724
Likes: 23
From: Minnesota
So just to make sure we are on the same page. I don't have any problem with getting the pump into the cell, but the mounting surface of the pump assembly won't sit flush against the cell, it pretty much stops short 1/4" from the cell.
Did you have the same problem?
Do you know what its hung up on?
Did you have to drop the fuel cell or rear cradle in order to insert the pump straight in without having to rotate it?
Thanks for the help.
Did you have the same problem?
Do you know what its hung up on?
Did you have to drop the fuel cell or rear cradle in order to insert the pump straight in without having to rotate it?
Thanks for the help.
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Thread Starter
Drifting
Joined: Oct 2006
Posts: 1,724
Likes: 23
From: Minnesota
Can anybody think of any reason why the fuel pump mounting plate fails to sit flush against the fuel cell?
I've removed the fuel level float assembly completely.
I'm certain the fuel sock is located properly.
I've removed and reinstalled the pump assembly no less than 20 times now.
Someone has to know what is going on. Please folks, I need help with this.
I've removed the fuel level float assembly completely.
I'm certain the fuel sock is located properly.
I've removed and reinstalled the pump assembly no less than 20 times now.
Someone has to know what is going on. Please folks, I need help with this.
