Had the dreaded fuel pump issue. Followed the procedure johnnycat8 posted here: http://www.rzrforums.net/engine-driv…fuel-pump.html
The brass nutserts were a problem as usual since Polaris chose to use thread locker on the bolts. Four of the six were locked into the nutserts and had to be pried off the fuel tank. Reset them with JB Weld and bought a $14.95 fuel pump off Ebay. Pump now works fine, but would’t hold pressure. The pressure regulator failed. Couldn’t find a replacement with the same rating of 270 KPa and the part number on the Polaris fuel pump assembly doesn’t exist nor is there a cross reference that I was able to find. After a lengthy search I found a similar fuel pressure regulator with a rating of 3 Bar. Turns out 270 KPa is 2.7 Bar. 1 Bar = 14.5 psi, so 3 Bar = 43.5 psi. Not quite 39 psi, but close enough. Part number is 0280160557. Fits a VW Jetta Mk 3/Mk4, 1.8T and 2.0L engine. $34.43 on Amazon Prime. Installed it and now the fuel pressure test yields exactly 43.5 psi. It looks slightly different with a hose barb for the overflow exit, but does not interfere with re-installation.
The brass nutserts were a problem as usual since Polaris chose to use thread locker on the bolts. Four of the six were locked into the nutserts and had to be pried off the fuel tank. Reset them with JB Weld and bought a $14.95 fuel pump off Ebay. Pump now works fine, but would’t hold pressure. The pressure regulator failed. Couldn’t find a replacement with the same rating of 270 KPa and the part number on the Polaris fuel pump assembly doesn’t exist nor is there a cross reference that I was able to find. After a lengthy search I found a similar fuel pressure regulator with a rating of 3 Bar. Turns out 270 KPa is 2.7 Bar. 1 Bar = 14.5 psi, so 3 Bar = 43.5 psi. Not quite 39 psi, but close enough. Part number is 0280160557. Fits a VW Jetta Mk 3/Mk4, 1.8T and 2.0L engine. $34.43 on Amazon Prime. Installed it and now the fuel pressure test yields exactly 43.5 psi. It looks slightly different with a hose barb for the overflow exit, but does not interfere with re-installation.
