How to Replace a Fuel Pump on a Classic VW Beetle (DIY – Pressure Test & Regulator)

How to Replace a Fuel Pump on a Classic VW Beetle (DIY – Pressure Test & Regulator)

Hi Everyone,

We have Miss Lemon Drop back in the garage for a fuel pump replacement. You may remember that she pooped out on the way home and Heidi and I got her running again. The owner (Jerry) purchased a new pump “kit” with the pump, rod, spacer and gaskets. I go through the installation of the pump, and also a check of the fuel pressure. That was the big surprise! At 5psi, it was twice what the carburetor specs. VW says to add a gasket or two to raise the pump and thereby limit the rod throw to lower the pressure. The problem with these aftermarket pumps is that if you go the route, you will have to grind the rod so much to get the pressure down, the flow will be too low to support the needs of the engine at running RPMs. The only real solution is to install a pressure regulator to meet the requirements of the float bowl needle and seat in the carburetor while still maintain adequate flow.

Tools and parts:

• EMPI 9092 fuel pressure regulator with bracket and 2 5/16″ fittings: https://goo.gl/1egzmp
• HFS (Tm) Carburetor Carb Valve Fuel Pump Pressure & Vacuum Tester Gauge Test Kit: https://goo.gl/wZZmZy
• Air cooled VW bug beetle fuel pump kit with flange & rod, generator style: https://goo.gl/7qDcnC
• 1/2 In Drive Digital Torque Adapter by USATNM: https://goo.gl/vEZ4mc
• Permatex 80016 Form-A-Gasket #2. 3 oz.: https://goo.gl/t5bH4z
• LDR 516 F146 ¼ Inch ID Fuel Line for Small Engines 6-Foot Length: https://goo.gl/i2WEyt
• Jmf Hose Barb 90 Deg. 3/8 ” Hose Barb X 1/8 ” Mpt Yellow Brass 150 Psi Lead Free: https://goo.gl/FoSj4k
• Koehler Enterprises KE4SS Hose Clamp Blister Pack, 4 Piece (Micro Size 4): https://goo.gl/chZpPw
• The Extinguisher we have in every car: Amerex A384T, 1.4lb Halotron I Class B C Fire Extinguisher: https://goo.gl/1dkRVJ

• 13mm Socket
• ¼” Universal Joint
• ¼” socket or nut driver for hose clamps

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Heidi and Franny’s Garage.

Disclaimer:
Due to factors beyond the control of “Heidi and Franny’s Garage”, We cannot guarantee against improper use or unauthorized modifications of this information. “Heidi and Franny’s Garage” assumes no liability for property damage or injury incurred as a result of any of the information contained in this video. Use this information at your own risk. “Heidi and Franny’s Garage”recommends safe practices when working on vehicles and or with tools seen or implied in this video. Due to factors beyond the control of “Heidi and Franny’s Garage”, no information contained in this video shall create any expressed or implied warranty or guarantee of any particular result. Any injury, damage, or loss that may result from improper use of these tools, equipment, or from the information contained in this video is the sole responsibility of the user and not “Heidi and Franny’s Garage”.

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Comments

Heidi and Franny's Garage says:

Hi Everyone,

We have Miss Lemon Drop (1969) back in the garage for a fuel pump replacement. I go through the installation of the pump, and also a check of the fuel pressure. That was the big surprise! At 5psi, it was twice what the carburetor specs. VW says to add a gasket or two to raise the pump and thereby limit the rod throw to lower the pressure. The problem with these aftermarket pumps is that if you go the route, you will have to grind the rod so much to get the pressure down, the flow will be too low to support the needs of the engine at running RPMs. The only real solution is to install a pressure regulator to meet the requirements of the float bowl needle and seat in the carburetor while still maintain adequate flow.

Let me know your thoughts… Franny

Tools and parts:

• EMPI 9092 fuel pressure regulator with bracket and 2 5/16" fittings: https://goo.gl/1egzmp
• HFS (Tm) Carburetor Carb Valve Fuel Pump Pressure & Vacuum Tester Gauge Test Kit: https://goo.gl/wZZmZy
• Air cooled VW bug beetle fuel pump kit with flange & rod, generator style: https://goo.gl/7qDcnC
• 1/2 In Drive Digital Torque Adapter by USATNM: https://goo.gl/vEZ4mc
• Permatex 80016 Form-A-Gasket #2. 3 oz.: https://goo.gl/t5bH4z
• LDR 516 F146 ¼ Inch ID Fuel Line for Small Engines 6-Foot Length: https://goo.gl/i2WEyt
• Jmf Hose Barb 90 Deg. 3/8 " Hose Barb X 1/8 " Mpt Yellow Brass 150 Psi Lead Free: https://goo.gl/FoSj4k
• Koehler Enterprises KE4SS Hose Clamp Blister Pack, 4 Piece (Micro Size 4): https://goo.gl/chZpPw
• The Extinguisher we have in every car: Amerex A384T, 1.4lb Halotron I Class B C Fire Extinguisher: https://goo.gl/1dkRVJ

MILO MANX says:

Heidi and Franny Milo Manx likes your video! Great to see two great minds think alike. P.S. The alternator belt needs tightened.

Iowa Comm. Watch News Network says:

Great video, Thank you.

Tim Dolan - Email says:

Wow! Great work on the roadside and this shop video. Your planning, lighting, camera work and post are some of the best I have seen in this space.(many hours on your part) I bet if a bunch of subscribers all contributed a little money – we could buy you a 1969 bug so you could do more videos 🙂 :). Please consider doing more. thank you. Keep the shiny side up and the dirty side down. t,.,

Tomas A says:

By the way, do you have a video on removing alternator, and putting in a new alternator?. Also, there are many options: made in china, empi, bosch….which type should i go with? Also, 50amp, 75amp, 90amp??…how doni decide which amp to choose?

Tomas A says:

And nice video by the way! Very informative

Tomas A says:

Hi. Your fuel pump fit right in easy. My fuel pump required a bit of force, because the inside lever was sticking out a bit. I hav a 72 ghia with alternator. I got my fuel pump from o’reillys. There system said it was the correct pump. My engine runs, but immconcerned about the fuel pressure…

New Jack says:

Finally someone who takes their time and actually show you how to wrench … A++

W Tski says:

Why would you grind any rod? Rock Auto for less than two bucks and at your doorstep in three days. Buy a spare or two.

Also I own an 82 911SC. Any videos on that generation?

O Esmerilhador says:

Thank you, greetings from Brazil

Mike Hammer says:

Is it me or was your fan belt too loose. Did you adjust it in a later video?

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