[jheis]

My '89 5 spd developed a miss on acceleration. I figured the first line of attack would be to replace the fuel filter since I had one on the shelf.

That's when the fun started....

The "mechanic" who was in there before me apparently owned two pair of vice grips. He used one pair to round off the 17mm fitting on the hard line that threads into the filter and the other pair to counter-hold and bugger up the banjo. Everything was cranked down really, really tight.

I installed the new filter and now have a major fuel leak. Fuel is spraying out under pump pressure. It appears to be coming from around the banjo, but I can't really tell, since everything is wet and fuel is just spraying out. I've had it apart numerous times and have gone through about a half a dozen crush washers. The last several times I've pulled the whole assembly and re-assembled it on the bench - still no luck.

I thought that maybe the hard line had been distorted from being mangled and over torqued, so I got a used one from 928 Int. I used Dr. Bob's tip of using teflon paste on all the threads and contact surfaces, assembled it on the bench and stuck it back in the car last night. No joy - still have massive fuel leak - fuel spraying out under pressure.

I have not replaced the check valve or the thicker crush washer between the check valve and the pump. I have, however, anealed the washer twice.

I am at a loss and don't know what to try next.

I guess the likely suspects are are washer between the pump and the check valve, the check valve itself, or maybe the threads in the pump body were damaged from being over torqued.

Anyone dealt with this kind of a leak before? At this point I'm seriously thinking of becoming one of those "previous owners" putting the whole thing together with JB Weld...

An intervention would be appreciated.

James