Evening all. I'm posting to tell a tale of woe - and as ever to humbly seek knowledge and advice. For the last two days a friend and I have been working hard on our 1990 4x4 panda, replacing the cylinder head after a skim, and putting on a new fuel tank.

All was seemingly good, but after heading on our jolly way to Wales, we hear some nasty scaping sounds (like when the tyres rub the arches). Sadly this wasn't the case - the tyres (chunky mud and snow ones) were in fact rubbing on the rubber fuel filler pipe. Consequently when we filled up at the garage - we shortly after caused a scene - spraying fuel everywhere out of our now ruptured pipe.

For everyone's benefit - here's the sorry proof.



The Haynes and Porter don't offer any tips and instructions for replacing this pipe...so I'm wondering if anyone has any clues here. Obviously the bottom end is simple enough (though it looks like we probably didn't push the filler pipe snug enough onto the tank itself) - but its the fuel cap end that looks tricky, mainly in terms of access. Is this a DIY-able job or are we best handing over to the experts on this one?

As an aside - after replacing the cylinder head and reconstructing the top end of the engine (in the presence of a pro - who was satified with the job we'd done and how it was running etc) we found that fuel wasn't being drawn as it shouls. We have a see-through fuel filter unit - and where beforehand it filled to about 70% full when running - now it only appeared to be getting 10% full. We checked the fuel lines weren't twisted or anything and all seemed ok there. Any ideas? Is it possible that a badly fitted push-rod in the fuel pump could cause this - as this is the only potential cause we could think of?

Sorry for the massive post again. Any help appreciated..hope you like the pic.

Hell!...NOT a good day my friend.

I had the same problem with the fuel pipe a couple of years back. Knobbly tyres and weak rear shockers were the problem. I fixed the hole with a bit of plastic and evostick.

As for the fuel problem, have you checked the fuel pump itself ?...they are quite crude.

phatbenny said:

... spraying fuel everywhere out of our now ruptured pipe.

The Haynes and Porter don't offer any tips and instructions for replacing this pipe...so I'm wondering if anyone has any clues here. Obviously the bottom end is simple enough (though it looks like we probably didn't push the filler pipe snug enough onto the tank itself) - but its the fuel cap end that looks tricky, mainly in terms of access. Is this a DIY-able job or are we best handing over to the experts on this one?

Click to expand...

The way the pipe is secured at the top inside the wheel arch is a bit like one of those push fit "star washers".

I understand they're virtually impossible to get off without breaking the pipe, then the replacement pipe and clip is easy to fit:

https://www.fiatforum.com/showthread.php?t=15370

Thanks for the advice guys. Just what I wanted. Something to start on.
I think I'll go the replacement part route rather than the glue and plastic way. Does anyone have a 4x4 they are breaking or know of one in a breakers yard?

Hi again,
As John H pointed out, the best way to remove your pipe is to break it. Unfortunately, this also applies to any that you might find in a scrapyard.

I was worried about that, but was hoping that the breaking only refered to the big washer and that I could just buy that part. I'll probably end up buying the parts from a dealership. I was just hopefully wondering if anyone knew of an alternative source, that I could get the part from before the bank holiday weekend is over.
Thanks for advice.

You might be able to break the plastic on yours (to save the washer), then knowing what you're trying to do up there in all the dirt, be able to break the metal clip on the one in the scrapyard - to get the pipe out intact..

Maybe?

I wonder, if anyone has a Parts CD, whether they can check if the filler pipe for the 4x4 Panda is a common part with other fiats...thanks.

Yes, but I'd need a VIN number from your 4x4.

P.M. me if you're worried about publishing the number in public.

Thanks John,
have PMd you. I know it's a long shot but there aren't many Panda's in the scrap-yards round me. Plenty of other fiats though.
Cheers
Ben

phatbenny said:

Thanks John,
have PMd you. I know it's a long shot but there aren't many Panda's in the scrap-yards round me. Plenty of other fiats though.
Cheers
Ben

Click to expand...

Looks like it will be a long enough shot getting the right part from a dealer...

attached are the screen dumps - there seem to be 2 options for your Panda, each with 2 different pipes.

the other screen dump is from a 86 to 91 2x4, and that seems to have a choice of 2 also - but the numbers are all different.


Sorry

Looking at the fuel tank sensors it seems to be option 2. What does the three entries for part 12 mean. 3 components, or 3 choices?
I think option one is the fuel injection fuel tank.
Cheers
Ben

John H said:

attached are the screen dumps - there seem to be 2 options for your Panda, each with 2 different pipes.

Click to expand...

John - you've not gone to 'settings' and 'English' on the CD, have you?!

Doesn't look like it, does it

Still get the same number of pipes though....

phatbenny said:

Looking at the fuel tank sensors it seems to be option 2. What does the three entries for part 12 mean. 3 components, or 3 choices?
I think option one is the fuel injection fuel tank.
Cheers
Ben

Click to expand...

I'd guess two choices, as the third one is greyed out.

You can't get (out of date) prices on the greyed out parts...

that's odd, I can't price 7664257, only on the part 7697803.

Looks like 26UKP 3 years ago....

John H said:

Doesn't look like it, does it

Still get the same number of pipes though....

Click to expand...

Fair point!

My Italian is going to get neglected now...

LOL!!!

In Florence, my Italian consisted of:
-Ciao
-Bonjourno
-Lasagne
-Pizza
-Chianti

It could have been better

I'm going to be working with phatbenny to put right the fuel pipe disaster tonight. We've got hold of (hopefully) the right parts from Fiat (£40) and are setting to work in a couple of hours.

Has anyone ever experienced a similar problem with the tyre rubbing the fuel downpipe? Looking at the new part it does seem awfully flimsy - I'm thinking we'll be as well to lag/protect it in some way - so if any 'tyre chaffage' does occur, we'll at least get chance to investigate - before its worn through and started tipping fuel everywhere

Any suggestions about this? - I was thinking as a first step to slit open the old downpipe and just fit it over the new one - like a sleeve.

I suppose the best answer is to get the damned thing out of the way of the tyre!!!

Good news: Fuel pipe is very easy to change. Just snap the neck of the old pipe, it's the only trick. Also the pipe is prob the only replacement part you need to get.

Bad news: Upon examination of the new fuel tank and the old one it seems that the new one is poorly made and repsonsible for the damage to the filler pipe. Basically the neck of the side of the tank that the filler pipe attaches to, is not bent to the correct angle. It is about 15 degrees out horizontally and 5 degrees to high. The result is that this forces the filler pipe 5-6cm closer to the tyres. I'm therefore going to change my mind about recomending buypartsby.com for cheap panda fuel tanks, as the tanks are poorly made . I don't want anybody making the same costly mistake (about £40 for a new filler pipe). I guess the lesson is that if you choose cheaper non-fiat parts they will not be made to the same quality. Our only option now is to try and bend the neck of the new tank to the correct angle. The only way I can think of doing this is with a gas torch and a piece of pipe inside the neck. Any advice much appreciated.