I put on a new pump/filter bracket today, but one end of the filter was leaking, with brand new copper washers, tried some alternatives, even filed down little raised edges around the banjo hex, where a spanner had been used at some point and slipped, still no joy.
Tried about 20 different washers, no luck, then tried to bend one, jesus so bloody hard, so put them on the chain(a chain that hangs down in my garage, for spraying objects etc) heated to glowing red, allowed to cool on the bench vice, no more leaks, amazing how much softer it makes them, obviously the "new" ones I got were old stock new, so always worth a try if you have leaks, just don't be tempted to heat them on the car ha ha!!
tabetha

 

Im having this exact same problem with my new fuel pump on the Bonus turbo, just cant seem to get the fuel pump banjo to seal, ive tried sanding the faces of the hose eyelet so that theyre flat and clean, fresh copper washers, tried fibre washers as these were fitted to my old pump before i took it off the road. And nothing, still pissing fuel all over the floor. Been messing around with it for almost 3 afternoons now too grrr!

Figured the eyelet or whatever it's called is out of shape/not square hence not sealing.
Im going to try this out now, if it doesn't work it look like its new hose time!

Cheers for the advice Tabetha

 

Tabetha, you my friend are my fucking hero

 

I assume it worked then ?, got my leaks sorted then the fuel pump spat a biggee and is now broken and pulsing ha ha!!
The original copper is most likely C11000 tough pitch, as it's called, this can be re-annealed/softened as many times as you like, it won't affect it, it does NOT need quenching in water after heating, but doing so will not affect the hardness, it will still be soft when heated and quenched, just doesn't need cooling down.
I didn't realise how many coppers there were till I asked someone about the softening thing years ago.
tabetha

 

Worked a treat bud. Amazing how much softer they are after a quick blast of heat, I was shocked, could easily bend it in my hand but was rock solid before.

Feel like I wasted a small fortune buying new coppers when I could probably have just reannealed them all, wouldn't have been as bufty though

Unlucky re the pump, Ł100 for a new one isn't it? Managed to kill my very low mileage Bosch pump this weekend too, you can hear it trying to spin up, but just clicks away.

 

The 044 pump is nearer Ł140-Ł150, but Sytec and Walbro are very good makes, so will likely not go for a bosch pump, after opening up a old bosch pump I can see it is nothing special, and bosch imo has taken a serious nosedive in quality over the last 10-15 years, I would never in a million years buy another bosch washer dryer either 13 repairs in 2 years, then a new one needed, another Ł550, I don't suppose all this farmed out foreign labour making the pumps are much better, it is just a std roller pump, nothing at all to justify the massively inflated price imo.
tabetha

 

im going to give this a go tommorow as ive just fitted a 44 and new filter i had a good idea it was going to have at least one leak when started but noooooo it leaked from every feckin union lol, it was about 8pm at that time so i gave up until tommorow but was only going to sand then refit, but now ill give this a go and let you know how i get on

 

Tab,

Is there anything you dont know, or dont have a solution for? You are truely like a walking database of knowledge fantastic

 

i had some problem last year but i stopped mine leaking using dowty washers, they're a copper washer with rubber on

 

Just another point, are you sure it's the right thread your using?

 

And mines leaking again
Might have to try some of these dowty washers, where's the best place to get them?

 

Hi. I had this problem after purchasing a 044 pump and fitting kit. Leaked like a sieve. Bought some dowty seals for about 20p each and sealed up first time

 

Dowty washers are the way to go...
had same problem on my sons cossie 044 fuel pump,fitted new copper washers from ford
onto banjo fittings,pissed fuel all over the road,,
Dowty washers sorted out banjo leak first time!

 

Just be aware a lot of dowty seals are NOT fuel compatible, the most compatible are NITRILE.
Neoprene(black), EPDM, Tan Shotblast, Insertion rubber, Neoprene(white/food grade), Silicone, and lastly Klingerseal C-4324, should not be used with fuel, most will seal on a temporary basis, but not long term.
The problem is the copper often is NOT new, but years old, even when freshly bought, if heated to cherry red and allowed to cool will seal perfectly if not tightened overly tight.
tabetha

 

fecking pain in the bum those washers always leak

 

i heated mine today and gave them a quick sand and there was only a very minor drip on the fuel filter unions which contrary to what tabs said about overtightening, was cured by giving a reet good tighten lol!
but as mentioned above those rubber and copper washers wont seal for long

 

Royally fucked of with my fuel pump now. Can't get it to stop leaking and I've pretty much mullered all the copper washers I have.

Think the problems with the union that runs from the hose around the fuel tank, the union face has a thin edge at one side where the union has rusted away leaving the mating face more like an oval. Hence only having a small area to seal against one side.

Anyone have any ideas how I can make a temp fix whilst I look for a proper replacement hose with good union?

 

my pump itself didnt leak, just the filter, i also noticed the filter has two slightly smaller washers on the banjo bolts, the small ones go against the filter and the large ones go against the bolt heads