In-Tank fuel pump
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Porsche 928 GT

In-tank fuel pump removal

During a brief January thaw my car suddenly died.  Jumping the fuel pump relay did nothing to get the car running again, and when the pump was jumpered I couldn't hear the pump running.

Discussions on the PacNW928 mailing list revealed many "me-to's" with a note from Louis Ott that the usual cause in later models was deterioration of the hose connecting the in-tank fuel pump from it's fitting.  The loose pieces of rubber then get sucked into the external pump, causing it to lock up.

Sure enough, removal of the in-tank pump (pictured below) showed that the in-tank pump had come completely loose from it's fitting.

Fuel pump exposed

Removal of the cover exposes the fuel filter (top) and the external fuel pump (which appears dead).

Fuel tank fitting

After loosening the fuel tank cradle the fuel pump fitting is exposed. Tank has been mostly drained with a siphon pump and rear of car is jacked up.

Fitting removed

Well, as feared the hose connecting the internal fuel pump to the fitting has discintegrated. In addition, the two wires pulled loose from the fuel pump leaving the in-tank pump "dangling" in the opening.

OK, now what

Now I need to be REAL carefull not to push the pump into the tank where I won't be able to reach it!


Now I see why the wires pulled loose. There is something BLOCKING the bottom of the opening. Blurry picture, but it's the orange colored piece at the bottom of the opening.

Finally removed.

I pushed down the blockage with a screwdriver and finally pulled out the in-tank pump using a needle nosed pliers. Here's the pump and fitting with my watch for scale. Note that the rubber hose connecting the pump to the fitting is completely separated.

Wonder where the extra pieces of hose went?

I'd guess into the external fuel pump, which died VERY suddenly.