Fuel leak from fuel pump wiring

I recently detect a problem with a barely noticeable fuel leak under the tank. AFAIK, there are two potential leakage points that need to be repaired/resealed - quick release coupling and electrical line plastic barrel. Fortunately, both parts have replaceable o-rings so I decided to give it a shot. Due to greater resistance to chemicals and heat, I chose replacement Viton o-rings instead of standard nitrile rubber and silicone o-rings.

I took the opportunity to replace the cable sleeve that was damaged due to the gasoline leak. I used a high quality Teflon/PTFE silicone coated fiberglass sleeve 6mm which is a bit bulkier than the original but should be more adequate for this application.

Together with the cable sleeve, I also replaced the fuel pump connector with new AMP superseal connector and crimped new terminals because I noticed that the old terminals were inadequately crimped at the factory (torn wire seals) as you will see in the photos.

Tools and parts used:

- Pin punch (for punching out plastic barrel holding el. line)
- Circlip pliers (seeger)
- O-ring lube
- Viton o-rings (10x2 mm)
- AMP superseal 4 way connector + terminals
- Teflon/PTFE sleeve
- New quick release coupling (AP8104192, 1072003 FORD)


Photo 1 - Initial state, two points of leakage, destroyed cable sleeve
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Photo 2 - Circlip removed, electrical line plastic barrel pinched out
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Photo 3 - New Viton o-rings in place. Greased liberally and put back together, taking care not to pinch the o-rings.
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Photo 4 - Removed quick release coupling grub screw
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Photo 5 - Removed quick release coupling and fuel pump electrical connector
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Photo 6, 7 - Clearly visible damage to the silicone o-ring (due to long-term exposure to gasoline?)
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Photo 8 - Inadequately crimped terminals at the factory and torn wire seals
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Photo 9 - New quick release coupling (AP8104192, 1072003 FORD) and Viton o-rings
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Photo 10 - Installed new quick release coupling, grub screw tightened back with a few drops of Loctite 542 (resistant to fuel)
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Photo 11 - New cable sleeve slipped on, new terminals crimped
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Photo 12 - New terminals crimped
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Photo 13, 14 - ALL DONE!
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Photo 15 - Parts used
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Faruk

Nice. Incidentally the fuel spigot/QD coupling is also available as a Piaggio/Aprilia part.

Thank you Pete

Yes, I initially ordered the Aprilia part AP8104192 but later I have realized that there is an identical Ford coupling that is slightly cheaper

Faruk

Probably depends where you are in the world as well. I tried looking for the Ford part and it was bizarrely difficult to order it. You know? Midnight chicken sacrifice type complicated! Just silly. But this is Australia.....

Nicely done sir!!! I'm surprised you got such nice crimps on your connectors using that crimping pliers. I have the "proper" crimp tool and still struggle with those. Perhaps I should try doing it your way.

rick pope wrote:

Nicely done sir!!!  I'm surprised you got such nice crimps on your connectors using that crimping pliers.  I have the "proper" crimp tool and still struggle with those.  Perhaps I should try doing it your way.

Thanks a lot Rick!  

If by "proper" you meant ratchet type pliers, I completely agree. In theory, they should enable an even application of force on the terminals and thus better crimps, but I also struggle with them and I never got the impression that I really control the process. Probably due to the design of the pliers that enables partial automation of the process. So I still prefer crimping pliers as in the picture because they give me a better feeling (and feedback) when finishing, especially when working with small terminals.

Faruk

Wow nice job and well documented. Do you have a part number for the ford fuel coupler? Thanks

Hey Tinker, Fruk actually mentioned it twice in his first post... but here you go: Ford part# 1072003

Edit: Unless you are referring to the female part of the QR coupling that slips onto the elbow...

tinker wrote:

Wow nice job and well documented. Do you have a part number for the ford fuel coupler? Thanks

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Aprilia/Piaggio part #: AP8104192
FORD part #: 1072003

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GUZZI part #: 01106692 (GU01106692)


I hope this helps
Faruk

Thanks that’s great sorry I must learn to read more carefully!

Hi, I have a similar problem with my fuel pump assembly and when removing the tank I've managed to break the spigot..(I know everywhere and everyone says be careful coz it's easy to break but I've got sausages for fingers)
Does the spigot just pull straight out or is there some witchcraft required to remove it? I've removed the grub screw and tried pulling it out, but concerned more force may cause more damage

Thanks for any help arm suggestions

Disregard I didn't read it thoroughly.

There's a one-way star washer on it. Some members have had to drill it out, if it won't come peacefully.



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Beautiful documentation, thanks.