RTM Fuel Pump Sending Unit Feed Line Repair Kit: 1g DSM AWD/Galant

If you own a 1g AWD DSM (or Galant VR4) and you've ever taken a good look at your fuel pump sending unit, we hope you had a strong stomach 'cause they can get downright nasty with corrosion. Sitting on top of the fuel tank in a sunken area, any water that finds it way up there tends to pool right there and, over time, this inevitably leads to corrosion of the various metal components. Most famous for corrosion is the thin-walled steel tubing that makes up the fuel feed line and the nuts and studs that attach the sending unit to the top of the fuel tank. This corroded sending unit is bad enough if it's just sitting there. But the minute it's disturbed (to change the fuel pump for example) watch out! Can you say SNAP! 'Cause that's a very common outcome to the fuel feed line and studs when any pressure is applied to them.  If this is the situation in your case, all hope is not lost, 'cause RTM has your solution.

We've designed two different repair kits for the fuel pump sending unit:

• a repair kit that replaces a damaged stock fuel feed hard line
• a repair kit that allows you to replace any broken or missing studs

We sell each kit separately. This particular kit relates to the first kit: the FPSU Feed Line Repair Kit. For details on the Fuel Tank Stud Repair Kit please refer to the "Related products" link near the bottom of the page.

This kit is designed to replace the stock fuel feed hard line at the top of the sending unit with an -AN male fitting. The -AN fitting can then be used to plumb in an -AN fuel feed line. (RTM carries several fuel upgrade kits for this purpose. For details, please refer to the separate entries elsewhere on the site). While it IS possible to retain most of your stock feed line downstream of the sending unit, it's a bit cumbersome and it's not recommended. The kit is designed to replace all the stock hard metal line attached to the sending unit (both on the exterior and interior sides).

There are two main types of repair kit:

• where the -AN fitting points horizontally from the top of the sending unit
• where the -AN fitting points straight up from the top of the sending unit

The repair kit with an -AN fitting that points horizontally is comprised of:

• -6AN bulkhead fitting pointing horizontally from the sending unit (in colour of your choice)
• plastic sealing washers and nut used with above fitting
• -6AN to 8mm hose barb fitting
• small length of 8mm hose (in type of your choice) to plumb in your fuel pump
• hose clamps for above hose.

The repair kit with an -AN fitting that points straight up is comprised of:

• your choice of a -6AN or -8AN bulkhead fitting pointing straight up from the sending unit (in black only)
• plastic sealing washer and nut used with above fitting
• small length of 8mm hose (in type of your choice) to plumb in your fuel pump
• hose clamps for above hose

Here's a quick overview of the repair procedure:
1) Remove sending unit from tank.
2) Cut off the exterior portion of the stock hard line flush with the top if the sending unit.
3) Drill an approx 9/16" hole in the place where the hard line used to exit the sending unit (the drilling of this hole will also remove the portion of the stock hard metal line that sits inside the tank--this is fine since that portion is not used with this repair kit).
4) Clean up any corrosion around this hole (to provide a good sealing surface for the plastic washers).
5) Install the bulkhead fitting with a plastic washer on the inside and/or outside and tighten down the bulkhead nut (installed on the interior side).
6) Install the -6AN to hose barb fitting onto the interior side of the bulkhead fitting (necessary only with the horizontal bulkhead).
7) Cut to length and install one end of the 8mm hose to the hose barb on the above fitting and the other end to the output of the fuel pump.
8) Re-install sending unit. (We recommend a new sending-unit-to-tank gasket, for details refer to the "Related products" link near the bottom of the page).

NOTES on HOSE TYPE: 
In one of the drop-downs below you are prompted for "hose type".  This refers to the type of hose included in your repair kit.  Regular rubber hose is NOT designed to be submersed in fuel.  The Gates submersible hose IS designed to be submersed continuously in fuel.  Since this hose is located inside your fuel tank, it is HIGHLY RECOMMNED that you use the GATES SUBMERSIBLE HOSE with this kit.  We DO NOT recommend regular rubber hose with this kit, however, we offer it as an option for those wish to take advantage of the cheaper price of the regular hose.

NOTE: Photo is for display purposes and depicts the repair kit with -AN fitting pointing horizontally.  Be assured that your order will correspond to your selections in the drop-downs.

NOTE: -AN fitting pointing straight up available in black only.

Applications:
DSM (1990-94) AWD.
Galant (1988-93) AWD.

Several purchase options available.
Choose from drop-downs below: