There's a rubber pipe inside the fuel pump that carries fuel from the bottom "bucket" part of the pump up to the outlet tube (the one with the red/white plastic end-fittings that carry fuel to the fuel filter and then the injector rail).

The rubber pipe can split and so your petrol doesn't get pushed up to the top of teh pump... instead it leaks out and falls back into the petrol tank. The car can't accelerate as the more revs it has, the higher the fuel pressure and that means more petrol leaks out of the split in the rubber pipe.

If you lift the pump out as far as you can, you might be able to see whether the rubber pipe is split or not. It looks like normal injector hose (but it isn't "normal").

To replace the pipe you have to remove the pump from the tank.. but before you unscrew it, you first need to remove the fuel level sender tube (the smaller part, inside the fuel pump) since that goes in at an angle and the pump will not come out with the sender attached.

If you replace the rubber pipe, you *must* use rubber hose that's designed to be submerged in petrol (called "in-tank injector hose" or similar). Normal rubber injector hose will perish if you put it in petrol - only the inner lining of a normal pipe is petrol resistant and the problem will happen again after a few days.

New pumps have a plastic hose instead of rubber... so sounds like it's a common problem.

The biggest problem is removing the fuel level sender since it will be hard and brittle and you might damage the top fittings (you have to use a special key or drift it with a screwdriver). Also the rubber gasket around the fuel pump will "stretch" (because of chemical reaction with petrol) when you take it out and it's difficult to refit it back in the hole. If you can find a new gasket before you take the pump out, it'll help you to re-seal the pump retaining ring.

If you can't find an Alfa 155 pump.. (if you need a new pump) also have a look at Fiat Tempra, Tipo or Lancia Dedra. I have a Fiat Tempra pump in my car (same part, different box).

If the rubber tube isn't split, then the problem could be a blocked fuel filter (under the right hand side, where the passenger seat is).



Ralf S.

 

Had the problem with the fuel hose in tank on mine.

There is also the pressure regulator on the end of the fuel rail to think about.

 

Hi there RalphS and Celadon ! Thank you very very much. Yes, I already changed the fuel filter with a new Bosh original spare, but the one I took off had only 11000 kms, it was dirty but not much that I could think it was the guilty piece.
I also thought in the regulator valv that Celadon says, but it is not available here so I want to check out the pump first and the hoses like you say.
Any have idea how much a new fuel pump can costs ?

Thanks very much again, and RalphS, so long that I do not talk with you but you always give me a hand, so much appreciated, I lost my wife some years ago and I wasn´t so much pften here in this excellent fórum.

Take care

 

If you have a 16v engine, i think the regulator is exactly the same for 145/146/GTV, anything that had the Phase1 metal topped engine.

They were also used in the FIAT coupe, and lots of other manufacturers at a guess.

Have a search for bosch part no. 0280160515

 

Ah Delgado.. sad to hear about your wife..

For the fuel pump, if the rubber hose is split, you can replace the hose - you don't need to buy a whole new pump.

I found this example of the type of hose you want, from Australia. It can be submerged in petrol. A normal injector hose doesn't like to be submerged:


http://www.ebay.co.uk/itm/444-Serie...-Diesel-Fuel-Hose-/151177548749?pt=AU_Car_Parts_Accessories&hash=item2332e253cd

The biggest problem with pumps is finding one. There's a few second-hand ones around. They're all 18-20 years old now... but generally reliable so they should still be okay. My old pump had 300,000kms on it.. but I changed it when I found a new pump, otherwise it was still working okay.

Ralf S.

 

Thanks very much both of you.

I used the Alfa Romeo scanner today and it was 0 error ! All was Ok today but It is not good when she is at 900 rpm. She has not the serenity ....... I feel it in my body.
I will look at the Bosch spare to have piece in mind and I Ralf, I like the australian hose ! It is the correct internal size to use in the pump ?

300.000 kms ! My God !I have 59.750 kms today so It has several years to use no ?
I added a Liqui Moly inyector cleaner the other day also, I do it always at 1.000 kms to help to mantain out the dirty things.

Thanks very much.

 

Hi Delgado.. I can't remember the internal size of the hose. I think it's 8mm but it might be 6mm. I'll have a look at my old pump next weekend and measure it.. but I suppose these guys could supply 6mm hose too, if that's the size.

I'm sure you can find the same type of hose in Uruguay too.. I posted that link so you could understand that it's not a "normal" injector hose. It's designed to live inside petrol.

The hose is just about 10cm long.. from the bottom of the pump to the top, so you don't need much.

If you find a Bosch fuel pump for the 155, post the part number so other people know it. I bought the last "Alfa" fuel pump in the UK (actually it was very old stock and boxed "Fiat" for a Tempra - same part) so there's none left from the dealers in the UK any more.



Ralf S.

 

If it's the same as a Tempra, there's a few of them listed on ebay...

http://www.ebay.co.uk/sch/i.html?_trksid=p2050601.m570.l1313.TR0.TRC0.Xfuel+pump+fiat+tempra&_nkw=fuel+pump+fiat+tempra&_sacat=0&_from=R40

 

It's the same as *some* Tempras (155 v6 vs. 2.0 ltr Tempra if I recall.. ) I'd suggest check the part numbers first on Eper.


Ralf S.

 

Yes, just yesterday I knew that here in my country are the fuel hoses, I supposed that not but yes here they are. Just a minute ago called the mechanic but he is Too Busy so I do not know when we van take out the pump and look at the state it is. Yesterday she worked very bad......... and then suddenly all was in good condition, I really do not understand too much how it is posible.
Celadon, I worked about the pressure valv regulator and find that is the same that uses the Reanult Clio and the Peugeot 309 and Citroën Xsara. But 2 spare houses I called do not have it in stock.........
About the alfa pump fuel spare number in eper is 60812839 but not know about the Tempra number......
Well fellows, we will be in touch, thanks for all very much.
Jorge

 

The Fiat Tempra 1750/2000cc used pump #7779449

Fiat Tempra 1370/1580cc was #7555130 (a metal cylinder type pump) so it's completely different.


Pump #60812839 was replaced in the Alfa 155 by part #46437229



The Fiat Tipo 1750/2000cc used fuel pumps with part numbers:

46402826 - replaced by 7779449
46413630 - replaced by 7779449
7779449 - replaced by 46437229....
and of course 46437229. Same as 155.


So... any Tipo/Tempra 1750 or 2000cc fuel pump will fit 155. They had Tipo in Brazil (not tooo far from you) and there is a Fiat factory there, so you have a great chance to find a new one..

Ralf S.

 

Here's the pump. The tube that splits is no. 23

The rubber gasket that sits under the ring nut (if you can find a new one) is no. 3.




Ralf S.

 

Yep thats the one that was damaged on mine.

it was caused by the pipe rubbing on the metal support braket (no.11 above).

I managed to fix mine by using a soldering iron to weld the hole. that was 2 years ago, and has been ok since.
I also made sure that the pipe was no longer rubbing.

 

Hi there Celadon and Ralf S and all fellows of course.
Well, I finally managed to take the fuel pump off ! The rubber cover that go all around the pump was really in very bad condition, so I think that this dirty rubber that the pump sucks was the cause of the faulty pump. so I fixed the pump tightly without that rubber and now I did 150 kms OK.
Suppose that the effort worths and was the only thing I can do because the Punto 1750 and the Tempra 2000 never came to Uruguay and I called the Alfa spare in Argentina and they does not have any pump in stock.........

 

here are 2 pics of the fuel pump

 

Hi fellows ! Today I received a new ePer new edition , and you know what ? I had a look at the fuel pump in the DVD and it is not available in the world ! Can you believe it ?:tut:

 

Yes.

155 has been out of production for the last 18-19 years.. so it's a huge problem now, to get some parts.

Does your pump work okay though? It looks like it has the later (?) plastic tube, rather than a rubber one.

The fuel pump rubber gasket might be easier to find... I hope that it fits more models, if if they used a different pump.


Ralf S.

 

Hi Ralf S !

Yes, it is working OK now but.......you know.......
The rubber gasket I found it in Buenos Aires and they are going to send me in ten days.......
Yes, it has the plastic tuve by fortune.
Tha bad part is that I did not remind to write the fuel pump Bosh number when I had the pump out in my hands !

I want to buy another pump but I need the Bosch number to compare......
And now I have another Little problema with the fuel filter, I changed it last month and used the last one and it does not exists here or in Argentina and nothing similar that I know for now.

Thanks very much for your help.
Take care.

 

When the gasket arrives, you'll have to take the pump out to fit it... so you can read the number then.

Make sure that the housing and the pump are both cleaned of petrol before you fit the gasket. As soon as it touches petrol it seems to "grow" slightly and then it's difficult to get it into the hole of the fuel tank.

It's strange .. but there's nothing else that can seal the petrol tank (I tried a few types of silicon sealants etc... but petrol dissolves everything).

So.. be kind to your gasket.. and once you fitted it, you should try to never remove it again.



Ralf S.

 

Fuel filters.... is an easy one. Service parts are not too bad to get.

There's thousands on fleabay (UK at least).


http://www.ebay.co.uk/itm/ALFA-155-...arts_SM&fits=Car+Make:Alfa+Romeo|Model:155|Cars+Type:2.5+V6&hash=item5d46bdd7e4

If you search for Mahle KL94 (the filter here) you can see all the other Fiat/Alfa cars it fits. Looks like nearly everything Fiat/Alfa made in the 1980's/90's used this filter....

You can also try out www.shop4parts.co.uk. Check your part number on ePer.. but if your filter is: 71736105 (or 60801638 or 60537455 .. older numbers) then search for part number S4P441.

The Brazilian 155 had a different filter.. so avoid that one.. (maybe for Ethanol? I dunno...)


Ralf S.

 

Hi Ralf S !
THe Mahle KL94 is a different filter but the S4P441 you mention is it ! I am going to contact these men to know if they can deliver ti to Uruguay because Argentina is in the list that is our neighboor but we are not listed.
About the rubber i wonder if it is not a good idea to keep it till i have to take out the fuel pump to change it or for another cause, because the actual rubber gasket is not 10 points but yes it is 7 and you know how difficult it is to change it............so.......There is nothing that can survive petrol.............
We will be in touch and thanks very much for all your help again.

 

I can't find a picture of the KL94... but I had a look for it on Opie Oils website (it belongs to "Oilman" on this forum) and it does come up as the filter for the 2.5 v6. You can search here:

Mahle Fuel Filter KL94 (Alfa Romeo, Fiat)


But anyway.. you can see, there are plenty of filters around somewhere in the world at least..

If they can't post it, let me know and I'll stick it in the post for you. Can't be toooooooo expensive, can it?


Ralf S.

 

Here's a grainy photo of the KL94..

It fits Fiat:

60801638 - the same part number as in my post #20.
8241687
82416870

Also fits Saab 8319733 so maybe a Saab dealer (in Montevideo??) might have a Saab filter.


Ralf S.

 

Hi Ralf S, yes i know, but remember that my 155 is the 2.0 16 valv. model 1997 and I think that the 2.5 V6 is different like a friend that has one in Buenos Aires tells me.
Looking at the image you post it is the same, but..........

 

Hi Ralf S, yes i know, but remember that my 155 is the 2.0 16 valv. model 1997 and I think that the 2.5 V6 is different like a friend that has one in Buenos Aires tells me.

I thought you had a v6? What happened to it?



Ralf S.

 

No Saab does not exists here..........:tut:

 

hi Delgado,
Have a look for the fuel filter type : Mann WK613/2...

this will fit, according to the website I looked on, many cars with the following part numbers ....

ACDELCO FS9257E Fuel filter
ALCO FILTER SP-2080 Fuel filter
ALFA ROMEO 464605 Fuel filter
ALFA ROMEO 60537455 Fuel filter
ALFA ROMEO 60801638 Fuel filter
ALFA ROMEO 71736105 Fuel filter
ALFA ROMEO 82392325 Fuel filter
ALFA ROMEO 8241687 Fuel filter
ALFA ROMEO 82416870 Fuel filter
ALFAROME/FIAT/LANCI 60801638 Fuel filter
ASHIKA 30-03-388 Fuel filter
AVA QUALITY COOLING FT5205 Condenser, air conditioning
BOSCH 0 450 904 159 Fuel filter
BOSCH 0 450 905 005 Fuel filter
BOSCH 0 450 905 021 Fuel filter
CHAMPION L203/606 Fuel filter
CHAMPION L205/606 Fuel filter
CHAMPION L218/606 Fuel filter
CLEAN FILTERS MBNA 955 Fuel filter
COMLINE EFF055 Fuel filter
COOPERSFIAAM FILTERS FT5205 Fuel filter
DENCKERMANN A110030 Fuel filter
DONALDSON P550012 fuel filter
DONALDSON P550094 fuel filter
DONALDSON P550152 fuel filter
DONALDSON P550272 fuel filter
DONALDSON P550498 fuel filter
DONALDSON P550587 fuel filter
DONALDSON P550588 fuel filter
DT 1.10064 Piston, air compressor
FIAAM FT5205 Fuel filter
FIAAM FT5261 Fuel filter
FIAT 60537455 Fuel filter
FIAT 60801638 Fuel filter
FIAT 71736105 Fuel filter
FIAT 82392325 Fuel filter
FIAT 8241687 Fuel filter
FIAT 82416870 Fuel filter
FILTRON PP827 Fuel filter
FILTRON PP829 Fuel filter
FILTRON PP833 Fuel filter
FRAM G5311 Fuel filter
HENGST FILTER H85WK01 Fuel filter
HOFFER 4040 Fuel filter
HOFFER 4040/1 Fuel filter
JAPCAR B3D009PR fuel filter
JAPCAR B3W014PR fuel filter
JS FS6042 fuel filter
KAGER 11-0069 Fuel filter
KAGER 94-5140 Condenser, air conditioning
KNECHT KL 204 Fuel filter
KNECHT KL 5 Fuel filter
KNECHT KL 63 Fuel filter
KNECHT KL 63 OF Fuel filter
KNECHT KL 94 Fuel filter
KOLBENSCHMIDT 40201 Piston Ring
KOLBENSCHMIDT 50013159 Fuel filter
KOLBENSCHMIDT 50013273 Fuel filter
LANCIA 60537455 Fuel filter
LANCIA 60801638 Fuel filter
LANCIA 71736105 Fuel filter
LANCIA 82392325 Fuel filter
LANCIA 8241687 Fuel filter
LANCIA 82416870 Fuel filter
MAGNETI MARELLI 150020009600 Fuel filter
MAGNETI MARELLI 153071760199 Fuel filter
MAGNETI MARELLI 154066937740 Fuel filter
MAGNETI MARELLI 154087186030 Fuel filter
MAGNETI MARELLI 213908500500 Fuel filter
MAHLE KL 63 Fuel filter
MAHLE KL 63 OF Fuel filter
MAHLE KL 94 Fuel filter
MANN-FILTER WK 618 Fuel filter
MAXGEAR 11-0049 Shock Absorber
MAXGEAR 11-0069 Shock Absorber
MEAT & DORIA 4040 Fuel filter
MEAT & DORIA 4040/1 Fuel filter
MECAFILTER E16 Fuel filter
MECAFILTER ELE6012 Fuel filter
MULLER FILTER FB196 Fuel filter
OE 25055846 Fuel filter
OE 25055847 Fuel filter
OE 60537455 Fuel filter
OE 60801638 Fuel filter
OE 71736105 Fuel filter
OE 82416870 Fuel filter
P.B.R. AG-6007 Fuel filter
PURFLUX EP161 Fuel filter
PURFLUX EP91 Fuel filter
PUROLATOR F58030 fuel filter 2.5 V6/1.3-1.6 8v Boxer Fram
QUINTON HAZELL WF8031 Fuel filter
SOFIMA S 1506 B Fuel filter
SOFIMA S 1511 B Fuel filter
SOFIMA S 8500 NR Fuel filter
TECNOCAR B96 Fuel filter
UFI 24.351.00 Fuel filter
UFI 31.511.00 Fuel filter
UNIFLUX FILTERS XB19 Fuel filter
UNIFLUX FILTERS XN300 Fuel filter
VOLVO 464605 Fuel filter
WIX FILTERS WF8029 Fuel filter
WIX FILTERS WF8031 Fuel filter


the site was a VW parts site, so your search may be easier than you first thought.

have a look here

hoefully this will help.