Fuel leak in return line

Dimitri16V

Top Post Dawg
Joined
Jan 30, 2005
Location
DE
TDI
01 Golf, 04 Golf
The blue fuel return fitting that clips in the in tank pump is leaking
I removed the pump ( it is aftermarket replacement ) and there seems to be a check valve in the return tube
Can I drill it out or the system will loose prime ? I blew some compressed air thru it and it seems to open fine
 

Dimitri16V

Top Post Dawg
Joined
Jan 30, 2005
Location
DE
TDI
01 Golf, 04 Golf
Removed the check valve and the leak is now minimized but still weeps some fuel
Anybody knows the O ring size inside the clip connector or the part number for the blue return from the tank to the cooler ?
 

Dimitri16V

Top Post Dawg
Joined
Jan 30, 2005
Location
DE
TDI
01 Golf, 04 Golf
ordered both supply and return lines from 1stvwparts.com

hoping it is not the neck in the pump assembly
 

Dimitri16V

Top Post Dawg
Joined
Jan 30, 2005
Location
DE
TDI
01 Golf, 04 Golf
hopes dashed , there is a fine crack on the return nipple on the pump assembly
I replaced the pump 2 yrs ago for the same issue and I am not willing to fork another $ 200 for the same crappy plastic VDO pump
can I use a gasoline model pump and transfer the electric pump assembly or they are not compatible ?

outside flange diameter seems to be 123mm
 
Last edited:

wonneber

Top Post Dawg
Joined
Oct 12, 2011
Location
Monroe, NY, USA
TDI
2014 Jetta Sportwagen, 2014 Tiguan,2003 Jetta 261K Sold but not forgotten
Gas pump

The only thing I would watch is the pressure & GPH
Gas fuel injection uses way to high pressure.
To much GPH might cause leaks up front by the fuel filter O-rings.
I would also wonder about the small hoses between the injectors & returning to the injector pump. They only push on.

Hmmm
I'm thinking to much. :)
Rich W.

hopes dashed , there is a fine crack on the return nipple on the pump assembly
I replaced the pump 2 yrs ago for the same issue and I am not willing to fork another $ 200 for the same crappy plastic VDO pump
can I use a gasoline model pump and transfer the electric pump assembly or they are not compatible ?

outside flange diameter seems to be 123mm
 
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