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16v Rallye Conversions All you need to know about this very popular engine conversion

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Old 15-07-2007, 11:34 AM   #1
Lee C
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S1 - GTI/VTS Fuel Pump Modification.

As some of the S1 16v owners are having a few troubles with there fuel pumps surging and over fueling i thought i would do a pictured step by step guide to how to modify a GTI/VTS fuel pump into a S1 tank.

**Big thanks to Russ16v for the original instructions**

Take out the S1 pump by unscrewing the big round plastic cap and unclip the connector and fuel pipes.


Remove the float on the side of the 16v pump by removing the 2 clips and slide it down to remove it and cut the 2 thin wires.


Remove the mesh filter on the bottom of the pump, this also clips in.


Unclip the spring loaded top off the pump by unclipping the sides and sliding the pump out but becarefull not to lose the spring and seal.


Unclip the pump itself and slide the pump and holder out in 1.


Put the 2 pumps side by side and mark where the bottom of the S1 pump is on the 16v pump, then cut the bottom part of the 16v pump off.




File the edges off smooth where you have cut to avoid the little bits of filings getting into your tank.

Now put the pump back together the opposite way you took it to bits.


Put the pump back in the tank and screw it back down tight, its slighly smaller but it does fit. Connect the fuel lines back up taking note of the direction of the flow. Then i jubilee clip them back on as its hard to get the old clips to hold the pressure again.


Take the positive terminal off of your battery and cut the old connector off the S1 loom and use spade connectors to re-attach to the 16v pump. On my car the Green wire was negative and the white wire was positive. The 16v pump is a 4 pin connector, the inside 2 pins are the ones you need, look on the S1 pump and take note where the old wires connected to on the S1 pump and copy for the 16v pump.


Re-connect the battery and turn on the ingition and prime the pump and watch for leaks.
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Old 15-07-2007, 11:36 AM   #2
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**Mods**

Sticky?
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Old 15-07-2007, 12:22 PM   #3
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Interesting!

My S2 XS has separate pump and level indicator...I'm assuming similar to the S1 rallye e.t.c. even though the car was a 1.6 8v to start with. Its always overfueled slightly....could this be the reason? the original was only a 90bhp lump so could the pump be the cause??

If so I may well try this out
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Old 15-07-2007, 02:25 PM   #4
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Quote:
Originally Posted by Azmo View Post
Interesting!

My S2 XS has separate pump and level indicator...I'm assuming similar to the S1 rallye e.t.c. even though the car was a 1.6 8v to start with. Its always overfueled slightly....could this be the reason? the original was only a 90bhp lump so could the pump be the cause??

If so I may well try this out
The pump can never cause overfuelling as no matter how high the pump flow is, the fuel pressure regulator will always keep the pressure at the injectors the same.
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Old 15-07-2007, 06:40 PM   #5
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fair play then, so no point in looking into a swap then?
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Old 15-07-2007, 06:49 PM   #6
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Nope definitely not.

Your Xs probably used a 3.5 bar though, and the vts uses a 3 bar, but seeing as you had a blacktop engine originally i presume you have a return line and the 3 bar in the vts rail is doing exactly what it should, rather than this silvertop wrongness with no return line etc...

So no don't bother unless you get fuel starvation in hard cornering which is highly unlikely anyway.
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Old 17-07-2007, 10:58 AM   #7
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yep I have a return line and never have had fuel starvation.

cheers for that mate, usefull as always
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Old 17-07-2007, 03:05 PM   #8
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Cured my starvation.
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Old 30-12-2007, 06:06 PM   #9
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this should be a sticky tho :P
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The Car In Front's A 16v.
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Old 30-12-2007, 06:11 PM   #10
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so what will happen if u put a 3.5 bar regulator on a 16v, other than just waste fuel will it go better... or just over fuel...
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Old 30-12-2007, 06:21 PM   #11
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overfuel probaly
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Old 30-12-2007, 09:41 PM   #12
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thread is stuck lol, good info there lee
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Old 06-07-2008, 09:45 PM   #13
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Have many people had problems using the 1.3 pumps?
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Old 22-07-2008, 12:47 AM   #14
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would like to know too
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Old 22-07-2008, 08:17 PM   #15
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Unless the rallye pump is faulty, there is no need to replace the fuel pump - The flow rate and pressure are both perfectly adequate for a 16v. If you are having problems you might as well go for another 1.3 fuel pump and save faffing about.
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Old 19-08-2008, 09:46 PM   #16
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i bourght a welbro motorsport fuel pump any ideas how to fit it? as its totally diffrent..?

ill get pics when i get my car back.. obv no instructions? but its says its a drop in replacment up to 300bhp fuel flow direct replacment? humm
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Old 23-02-2009, 08:49 AM   #17
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Would a VTS fuel tank be an easier option? If so i'll just get a tank with the pump in and plug away...
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Old 11-02-2012, 11:11 AM   #18
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Hello guys. I installed the 1.3 s1 rally tank with pump and fuel level in the 1.6 16v. now I can not see well on the dash how much fuel I have in the tank. as do the full and the indicator is in the middle, when it is dry according to the indicator in the tank there are still 20 gallons if not more. What can I do? thanks
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