So got my new fuel pump rebuild kit today..........

[Mr. 856 170]

This rebuild is going to fight me to the end. Maybe I should start thinking about a complete engine swap? DOOOHHH!!!

Recieved my new fuel pump rebuild kit today. Filled with anticipation for a fun packed friday night of rebuilding my fuel pump I ran into this little problem right from the start.

The holes are off in the gasket. The new gasket is also much thicker and made of a rubbery material. I didnt assemcle the pump completly but if i get all four screws in the body the gasket curls in the middle on every side because of the holes being off. Im assuming this aint right..........I also noticed in the kit the little disc inside arent the same material and the new ones are a bit small in roundness. Im emailed the seller to see if the mis-aligned holes is normal. Maybe the rubber material swuishes out? I would think any gasket be it rubber or paper should sit flat to the surfaces it trying to seat even without pressure. Maybe im just an idiot and dont know anything? LOL

So my fun packed friday night fuel pump rebuild came to a quick stop. Im now here wondering if I should just take this kohler and make a boat anchor out of it. This engine isnt playing nice......she doesnt want to get fixed up. Playing tough...........Im not giving up just yet. Guess ill go down stairs and beat my head against the bricks in the basemant now.

[rmaynard 16,184]

I had a similar problem with the kits that I got from Maritime to rebuild two K161 pumps. Yours is a vacuum type pump, mine are mechanical. I had mis-aligned holes too. To make them work, I had to enlarge the holes in the diaphragm.

On the other hand, when I rebuilt my K181 vacuum type pump last year, I used a diaphragm made by one our members, "buckrancher". It was a perfect fit.

[SousaKerry 502]

Well someone didn't calculate their tolerance zone correctly and should have used mmc to open up the holes to ensure a larger true position tolerance.....

I expect only 3 people on this board to get that gd&t joke

Yeah i would drill the holes out a little bigger and you should be fine, but the manufacturer needs to alter his die a bit to correct the problem I'm sure your not the only one.

[Mr. 856 170]

I had a similar problem with the kits that I got from Maritime to rebuild two K161 pumps. Yours is a vacuum type pump, mine are mechanical. I had mis-aligned holes too. To make them work, I had to enlarge the holes in the diaphragm.

On the other hand, when I rebuilt my K181 vacuum type pump last year, I used a diaphragm made by one our members, "buckrancher". It was a perfect fit.

I also got my kit from maritime.

[rmaynard 16,184]

Here's how mine looked.

[wp205a 43]

Punched mine out to fit with a gasket hole punch. Hang in there, something much worse than this will come up.

[Mr. 856 170]

SO.......little update. I tried punching the holes out a tad bigger. no go. Id literally have to punch holes over holes its so off. So i called the supplier and was told to give them dimensions for my hole center to centers and they would send me a new one today. My holes are 1-5/16"( ONE AND FIVE SIXTEENTHS). The old one was 1-3/8". doesnt sound like a lot but when its in every direction it makes only one hole line up properly. So today I get my new gasket with anticipation. Low and behold its the same if not worse then the first one. Clearly wasnt cut to the dimensions they asked me for. What the hell is wrong with people? They asked me for the dimensions, I provide them, get told all set sent out today, get the thing and its no better if not worse then the first one. AT this point Ive requested to return the dam kit for a full refund. Ive contacted a site member and will buy a few from him. Im sure they will fit. Should have just dont that the first time.

If anybody wants to know where NOT to buy a kit PM me.

[rmaynard 16,184]

Although the holes should be punched correctly in the first place, I had no problem enlarging mine. I would contact them again and ask to speak to Mike. He was very responsive to my concerns, and I think he is an owner.

[Mr. 856 170]

Have to send the kit back. After emailing back and fourth in regards to the 1st and 2nd gaskets not being correct, they want me to send them my fuel pump so they can rebuild it. At no cost to me...... except to ship it to them and they will use the kit they sold me. Im hesitant to do that and thats not what I should have to do in the first place. I turn wrenches and fix stuff every day far more complicated then this little fuel pump and certainly dont need someone to rebuild it for me. So I nicely asked instead If they would send me a piece or two of the diaphram material they are using so I can cut my own holes to line up. They said they are out of material now............just send the kit back. So that I will do. Ive ordered two gaskets from a memeber here and had I know they were available here prior I would have taken that route since really thats all I need is a gasket. I dont need to replace anything else. Im not one to bash small business's so I wont. However I will say that If anyone is looking for just a gasket to get them from the member here who sells them the first time. Unless you dont mind making a gasket that doesnt fit look like swiss cheese and compromising a good seal. On with the build I say.

Buckrancher..... we good?

[buckrancher 2,694]

in the mail today

[953 nut 59,211]

Try contacting "Then and Now Automotive", ljthen2@aol.com They have great kits for Kohler pumps. :flags-usa:

[rmaynard 16,184]

That's who he got the kits from.

[Mr. 856 170]

Yup what Maynard said. Maybe my fuel pump shrunk?? LOL Im obviously not the only person who has had the issue so my best guess is there machine or die is off. What really tickles me is getting a second gasket that was worse then the first after giving them my center to center dimensions on the holes.... Ive ordered many carb kits for all types of machines from wackers to snowmobiles and never have I had an issue like this with the gaskets or diaphrams not lining up. They are so simple to make if the material was readily available. Give me a razor blade and my wifes tack hole puncher and two minutes and i could make one. Thanks to Bunkrancher my fuel pump diaphram issues should be done with in a few days. :)