Mk2 Golf GTi 16v fuel pump housing leak

August 27, 2025, 01:14:36 PM

Hi all, I've had to replace the lift pump and the fuel pump / filter in my 16v mk2.

I think the increased flow and pressure has caused a leak to appear the top of the plastic pump housing.

I know that VW stopped manufacturing these so I guess I have two options:

1. See if there is such a thing as a second hand non-leaking housing
2. Buy an aluminium repo at around £450

Does anyone have any smart ideas, alternatively have experience in doing this? Taking out the housing and pumps etc should be no hassle but some guidance of what to look out for or change whilst doing the work would be great. What clamps to use and what grade and dimeter of hoses etc.

Cheers,

James.

Re: Mk2 Golf GTi 16v fuel pump housing leak

Reply #1 – August 28, 2025, 07:14:24 AM

To be honest, I'd probably bite the bullet and go for the ally one.
Any second hand one will be at least 30 years old at this point.
The aluminium one is a fit and forget item and very well made (fitted one to a mates car a few years back).

One other option, while it's a big faff, it might be a little cheaper:
Depending on what you can get, you could potentially fit a mk3 VR6 (or GTI) tank, it's got a fully internal pump setup, however it doesn't have the pressure (if memory serves, VRs are around 3-4 bar, k-jet needs 5). But you could possibly upgrade that pump to suit.
A tank will set you back about £130 and a pump around £100.