fuel sender / rusty pipes

300 tdi '97.
Mot man spotted some welding that needed doing on the chassis next to fuel tank, so the summer job of replacing boot floor pan was advanced. Fuel tank dropped for access for welding and floor pan now out.

Welding all complete. Main problem is the pipes on the fuel sender on top of tank were badly rusted and virtually snapped off ( previous owner had sealed with a load of silcone...)

So I have the new shiny sender in place but both pipes ends (the one to the sedimenter and the fuel return pipe) are f**ked... Can you buy fittings for these to go on the exisiting pipes? Or are new pipes required? If new pipe for fuel return required, is it one pipe from engine all way back to tank?

Sedimenter is in a right state also, worth replacing while floor out? Drain plug is seized. Can prob take apart to empty but the pipe fittings also rusty, so if replacing pipes....

One simple task of a weld is turning into a nightmare, but at least some long put off jobs are getting done ! ( new floor pan, cleaned and sealed chassis !)

Thanks guys

just checked with main dealer. replacement fuel return pipe is obsolete and cannot be ordered.

Help ! Anyone got a work round to attach fuel return pipe to sender - will jubillee clips be sufficent on the fuel system ?

andrew

you can get fittings and olives and some steel pipe but since you would have to hose clip to it you may as well run 2 x fresh lines and hose clip to sender and lift pump etc do away with sedimenter and go straight to pumps filter has water drain

Thanks James - I think you might be right to replace the lot ! I've seen a lot of chat about whether there is a need for the sedimenter, and the view is split 50/50. You reckon no need for it ?

Andrew

no you have a filter with drain in engine bay

When I replaced my sender (again like you came across it when changing boot floor) my pipes where knacked, so ran some new fuel hosing from the sender.....job done.

Also by-passed the sedimentor, and been running with no issues whatsoever since removing although I do change my fuel filter on a regular basis - about every 5k miles, since they are cheap as chips

Same as stu rox ran a complete new flexible fuel line from front to back just pushed the flexible line over the new pipes coming out of the sender and fitted jubilee clips! 10k miles and hasn't missed a beat

Thanks guys ! existing fuel lines will still meet the sender so jubilee clips it is !