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Discussion Starter · #1 · (Edited)
My fuel pump went out and in an attempt to justify the cost of repair I tried to do it as cheaply as possible. This is the result. Cross referencing the fuel pump part numbers I found that the 4.6 crown victoria used to use the same part number as one of the pumps that that was listed as a replacement for the 164.

So I went the the junk yard and picked up this fuel pump and pigtail out of a Lincoln Towncar. I didn't think to take pics until after the pump was put together cause I didn't think it would appear as viable.

http://i117.photobucket.com/albums/o48/comrade904/Alfa%20Romeo%20164L/2011-05-21170519.jpg

After getting the pump out of the Lincoln you have to remove the fuel strainer, then the thick rubber case it is in. After removing the rubber case I put the Lincoln strainer back on. I then put the Lincoln pump and strainer into the Alfa pump basket. As you might be able to see above the Lincoln pump is smaller than the Alfa pump, so I cut a 2"x 24" strip of heavy red rubber and wrapped it around the Lincoln pump so it had the same girth as the Alfa pump. See photo below to see the rubber I used.

http://i117.photobucket.com/albums/o48/comrade904/Alfa%20Romeo%20164L/2011-05-21170536.jpg

I know what you are saying, what if the rubber breaks down like the black Alfa rubber in the first picture breaks down. For that matter I didn't replace the Alfa's black rubber surrounding that broke down likely causing the death of the first pump. Below is a diagram I drew real fast.

http://i117.photobucket.com/albums/o48/comrade904/Alfa%20Romeo%20164L/pumpdiagram.jpg

I then pulled the rivets insulating the pump wires and connected the Lincoln pump's pigtail to the Alfa pumps pigtail, and ran the wires through the holes left by the rivets, Then I epoxied the holes so the wires would not rub against the pump plate. See below.

http://i117.photobucket.com/albums/o48/comrade904/Alfa%20Romeo%20164L/2011-05-21170554.jpg

http://i117.photobucket.com/albums/o48/comrade904/Alfa%20Romeo%20164L/2011-05-21170503.jpg

Finally, the plastic tab on the side of the plastic pump housing broke off so I got a screw and washer and screwed it together.

http://i117.photobucket.com/albums/o48/comrade904/Alfa%20Romeo%20164L/2011-05-21170702.jpg

So far so good, I'm only out $40 compared to the $115 for a "universal" or $150-$300 or more for a real Alfa part.

This repair isnt for every one but it was for me, and maybe some one else out there might find this is the repair solution for them so I will post it here in case. You do this on your own, don't sue me, cause I have no money.
 

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1991 164L
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So don't forget to go to Home Depot and get those neoprene and steel sealling washers for tank cover bolts and hope your epoxy sround wires sells wires so no fumes or liquid pass there either.

So does car now run?
 

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Discussion Starter · #3 ·
i never drove it that much so, i never paid that much attention to the fact that it lost steam around 4500-5500, sometimes it would pull longer that others. Now it seems to run out between 5500-6000. ive really been sure exactly how hard it was supposed to run. Before the pump went out it would occasionaly stumble under load as low as 2500. i am happy to say it hsnt done that since.

As far as the seal, it looked pretty good when i put it back and i epoxied from both the top and bottom.
 

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1991 164L
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Rev limiter set about 6200 on 164B/L.
 
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