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View Full Version : Fuel Pump Genie anyone!? Q about fuel tank cover



Kronic Budz
11-04-2013, 05:54 PM
ok so after endless attemps of getting my fuel pump in, id say im pretty confident about helping anyone to this job on an A4, and have the patience of a god!

So what is the problem? I am getting a fuel starvation/hesitation when my gas gauge gets towards 1/4 tank or so.

It is noticeable when in lower rpm's and in gears 1-3.

When doing my fuel pump for maybe the 100th time recently, in the picture below circled in red (fuel return), has two o-rings in it that helps secure it to the bottom of the fuel tank cap. Well I wasn't careful enough and busted one of those o rings, thinking it properly sealed when I finished the fuel pump job, i believe this is now causing this issue. If im not mistaken, this return runs into 2 hoses and distributes gas to each side of tank..?[confused]

pump is new, supply line from pump to tank cover has new oem rubber line and clamped down well, so is this my problem? better yet, how do I go about fixing this besides guessing an o-ring size or snatching this part off parted out a4 to get that return line to seal?

quattro car of course

BTW, this picture below isn't my car just a picture I could find so I don't have to start digging until I know i can fix it ;)

thanks guys! you da' bomb![drool]

http://s23.postimg.org/3lj31oujf/Pic15.jpg (http://postimage.org/)
image upload no ads (http://postimage.org/)

Seerlah
11-04-2013, 06:03 PM
Autozone sells boxes of assorted sized o-rings. I'm pretty confident one of them must fit.

Kronic Budz
11-05-2013, 12:24 AM
Ok ill swing by and check it out ^^^

But I have had also bad experience trying to match I ring sizes up in the past...

Anyone know what the return hose does?

Seerlah
11-05-2013, 01:56 AM
Just returns the fuel. Your rail feed line has an fpr. The pump flows at a constant rate, depending on voltage. This flow creates pressure. Once the pressure in the feed line exceeds the fpr setting, it then dumps the excess fuel back into the tank via return line to keep the feed line at a certain pressure.

Kronic Budz
11-05-2013, 08:20 AM
Just returns the fuel. Your rail feed line has an fpr. The pump flows at a constant rate, depending on voltage. This flow creates pressure. Once the pressure in the feed line exceeds the fpr setting, it then dumps the excess fuel back into the tank via return line to keep the feed line at a certain pressure.

So if that return line isn't sealed @ fuel tank cover or possibly not attached for all I know now, could it be making my fuel pressure spiking just enough to make it noticeable while driving?

Seerlah
11-05-2013, 04:07 PM
Not fluent on the fuel system that much, but I don't think so. All the return line does is dump the excess fuel back into the tank. The feed line is what is important for keeping proper pressure.

Kronic Budz
12-20-2013, 09:03 PM
Does anyone know what kind of clamps work to secure fuel supply line to fuel pump? Stock clamps are one time use style.

I have tried many types including European screw kind. And there is still a leak allowing fuel pressure to escape. Anyone else have any ideas for fuel pump assembles that don't come with supply line already attached and need need new clamps with the stock line to swap over?

RallyeBourne
12-20-2013, 10:45 PM
What pump are you using? Is it oem, or aftermarket? I'm not a genie, but to me, if it only happens below 1/4 tank or so, the the fuel pick up is not mounted low enough. If it's too high, then you'll have a whole bunch of fuel that your pump can't get to. I hope that makes sense.

As far as clamps go, they make clamps specifically for fuel systems. http://img.tapatalk.com/d/13/12/21/pasadeby.jpg

They have rolled edges so that you can crank them down without cutting the fuel line, and they actually use a small nut and bolt, instead of a screw, to tighten down. You can get them at any auto parts store. They are on the wall near the fuel filters. I actually found a case of assorted clamps. It was like $7.99. Stoked!!

EDIT: I put in an AEM unit for $100. It was easy and the car is running fantastic. I do have a lean issue, but that is because of a vacuum leak somewhere.

Kronic Budz
12-20-2013, 11:58 PM
I'm speaking of the clamps on the fuel supply line in the gas tank itself. The ones that need to handle all the fuel pressure coming right from the fuel pump. Plastic hose fitted on plastic fuel pump nipple.

Seerlah
12-21-2013, 06:30 AM
He is just using the pic for reference. The clamps he is describing are the correct ones to use. They call them fuel injection clamps (I believe). I ordered a bunch from ebay in different sizes a while ago to have around.

MooseWhip
12-21-2013, 07:50 AM
Do you have the sock clocked into the correct position?

Sent from my SPH-D710 using Tapatalk 2

Kronic Budz
12-21-2013, 09:07 AM
The only problem is that I can't find "fuel injection clamps" small enough.

Anyone know where I can find them? Online?

Mad Cow
12-21-2013, 09:17 AM
They're friggin everywhere, I had no problems finding a bunch of different sizes for when i was screwing with my fuel system. Any half-decent auto parts store would sell them. Try harbour freight too, it seems like that would be something they would sell in large quantities.

Seerlah
12-21-2013, 09:51 AM
Try Napa. Autozone has them also, but not by the regular worm clamps. They place them in some oddball places in the stores.

RallyeBourne
12-21-2013, 09:53 AM
I found mine on the same wall as the fuel filters and such. They came in a pack of two. Then, I found the big pack of multiple styles/sizes over by the racks of plastic trim snaps. Obviously, each store can be different. But that's been a pretty common layout around me.

Seerlah
12-21-2013, 09:58 AM
Have a couple Autozones in my city, and they didn't have them by the counter or other clamps. And Advanced Auto had them behind the counter. When my supply ran out, I just ordered a bunch in different sizes on ebay. Easier, unless you need them right away. Here are the ones I ordered.

http://www.ebay.com/itm/380490863782?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1497.l2649

There are also worm clamps that have rolled edges. German made. These things kick ass. OEM for some Mercedes applications. Brand name GEMI. Can't recall what site, but picked these up in various sizes also. Pic for reference.

http://s28.postimg.org/528f0o2vx/gemi.jpg

Mad Cow
12-21-2013, 12:36 PM
Have a couple Autozones in my city, and they didn't have them by the counter or other clamps. And Advanced Auto had them behind the counter. When my supply ran out, I just ordered a bunch in different sizes on ebay. Easier, unless you need them right away. Here are the ones I ordered.

http://www.ebay.com/itm/380490863782?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1497.l2649

There are also worm clamps that have rolled edges. German made. These things kick ass. OEM for some Mercedes applications. Brand name GEMI. Can't recall what site, but picked these up in various sizes also. Pic for reference.


Damn I need to get me some of these, so sick of having to make the drive to the dealership and paying $1-3 per clamp.

Kronic Budz
12-22-2013, 10:25 AM
But do fuel injection hose clamps work better than these!?

http://i587.photobucket.com/albums/ss315/12vpower/image_zps7607a82f.jpg (http://s587.photobucket.com/user/12vpower/media/image_zps7607a82f.jpg.html)

RallyeBourne
12-22-2013, 10:52 AM
Do you have the tool to install those??

blmlozz
12-22-2013, 10:57 AM
But do fuel injection hose clamps work better than these!?
they're equivalent.


Do you have the tool to install those??
you can use wire cutters in a pinch.

MooseWhip
12-22-2013, 10:59 AM
I have fuel injection clamps like the ones seerlah posted on my fuel pump and on a 5" section of line I had t cut out and put a rubber hose in its place at the filter do to a cracked fitting, thats what they are meant for. I personally hate the factory style crimp clamp, they are a pain in the ass lol

Kronic Budz
12-22-2013, 02:10 PM
Ok fuck it I'll try and take them back to the dealer and just get some smallll fuel injection clamps. How tight do you guys get the clamps on the fuel line without breaking the pump or cover?