[Mk2] [Turbo] **FIXED** *NO fuel coming out of return fuel rail line!

[Andy F]

Will be fine then Jim

Good luck with it mate, its not a hard job, just poo

Let us know how you get on mate

[jimGTS]

Will be fine then Jim

Good luck with it mate, its not a hard job, just poo

Let us know how you get on mate

the whole bloody world will know dude, this mystery has taken up nearly 4 months of my time and money!
Hopefully I've finally got to the bottom of it and can enjoy the car again.

[jimGTS]

before i dropped the tank, it was suggested on the US site to plum in the walbro right in the inline fuel line to the rail, use a hose and jerry can and just give power to the pump and see what base pressure i got, some good news

basically went, jerry can, pump in the jerry can, hose from pump to inline fuel line, that went straight into my fuel pressure gauge which finally ended at the rail

gave power to the walbro and i got 42psi of pressure!
when i turned it off it held a good 30psi of pressure (the bgb mention there should still be fuel pressure for 5mins after the pump has been turned off)

before this test when i got 10psi, soon as i turned it off it went straight back to 0.


i also pulled the outline from the rail, before i wasnt getting ANY fuel coming from this line, but now, YEY, was getting a load of fuel coming out of here.

unfortunatly in this testing process i managed to spray a ton of fuel over my engine, namely cam over and tb, which decided to bubble up my newly painted engine parts! DAM!!!

i decided not to try and start the car, as id rather this petrol dry up, plus i could really use a second pair of hands to hold the fuel pump, the lines and jerry can before everything decided to spill/tip over everything when i start the car...lol

[RobCrezz]

Shame about getting it on your painted bits, but at least it sounds like you are solving the fuel problem!

[jimGTS]

Ok bit of a mission, got the tank out today!

Nothing untoward, no kinks, splits, so I guess the pump is just weak.

I'll get some pics up of the pump I found in the tank.



That tank is heavy!!!! No Idea how I'm going to get it back in!
I'll try and pour what I can into the 2 jerry cans I have to lighten it up.

Prob 6-8hours and counting just to get the tank out, pmsl!

[Quigonjay]

just think how quick you will be able to do it next time though if ever you need to drop it again
had a tank out and back in in a morning
was it an uprated one then?

[jimGTS]

Maybe.
That ventalation thingy took me a while!! Lol. Is different to the guides i've read on my rev5.
That hardline to the filter. I couldn't undo that. Spent 2hours on that and rounded it off. Fortunatly for me I undone that line at the fuel filter instead and managed to thread it through everything thankfully.
So i would avoid that next time.

Rest is just time consuming but ok.

I'm quite frankly am amazed you could drop it AND put it back in a couple of hours!! This on stands or a lift???

Yeh pump us aftermarket, didn't need to take it out to tell me that tho. Lol

got some weird actuator/fpr like top end to it. Strange. Not seen a pump like that before. And no recognisable markings on it.
I'll get pics later

[RyanRs]

Jim, could you do me a quick favour while the tank is off?? Could you stick a tape measure or ruler down the hole in the tank (where you remove the pump from) and measure how deep the tank is. i need to get couple of pipes to make a pickup but dont have my tank dropped so i dont know how long they need to be.

thanks bud, good luck with the new pump!!

[Quigonjay]

it was on stands jim, i should probably mention there was no engine in the car at the time, forgot about that

[jimGTS]

it was on stands jim, i should probably mention there was no engine in the car at the time, forgot about that

that would make quite a bit of difference with no engine in the way, lol.
Tho for sure I'd no where to cut corners next time.

[RyanRs]

Jim, could you do me a quick favour while the tank is off?? Could you stick a tape measure or ruler down the hole in the tank (where you remove the pump from) and measure how deep the tank is. i need to get couple of pipes to make a pickup but dont have my tank dropped so i dont know how long they need to be.

thanks bud, good luck with the new pump!!

it that ok to do that jim? in case you missed it!

Btw, i got to take my tank out, is there any bolts / nuts that need unscrewing from inside the car, ie under the tunnel trim?

[jimGTS]

Thts ok I didn't miss it.
When I'm next by the tank I'll measure
nothing to undo in the cabin apart from unplugging the fuel pump connector and fuel gauge connector under the dash.

The rest is a pita.

[RyanRs]

The rest is a pita.

ah great lol. i must say. i have never heard anyone say ' That wasn't too bad' when taking the tank out!

Would you say that the majority of the weight of your tank was due to the fuel in it?

[jimGTS]

Am not sure yet. I'm going to drain the tank out before I pop it back in. I'll have to see how much weight that does save.
It is all metal the tank, so it will weigh a bit, I was suprised as it weighed a ton even with 1/4tank in there.

[Quigonjay]

as little fuel as possible in the tank
it is not actually that heavy on its own out of the car but when you are underneath holding the front of the tank on your knees and trying to bolt up the back, it can get a little heavy

[jimGTS]

I can imagine!
Misses will come useful with any luck!!

[jimGTS]

this is what i found in the tank

ryan, theres a depth of around 10-11 inchs from top of tank to lowest point in the tank for the pump







size difference between old pump and new walbro

[Quigonjay]

I can imagine!
Misses will come useful with any luck!!

lol, you worried she might have seen that?
you tried putting the bip pump part number in to google?

[RyanRs]

Cheers jimbo! great help!

Btw, Jees! that pump looks a beast! shame it dont work. I wonder if the reason its packed up is to do with such a 'possibly' high flowing pump trying to flow silly amounts of fuel through the tiny stock size fuel lines?!

You should get one of bobhatton's goodridge braided hose kits while you got the tank off. All braided 200 series hose with AN fittings, they look the nuts!

http://www.imoc.co.uk/forums/viewtopic.php?t=124183

Also jimbo, what are you doing with the old pump? if you are scrapping it, is there any chance i could have the sock off the bottom? thanks.

[jimGTS]

YEEHHHHHHH!!!


The beast is back!!!!!!!!!!!!

It was immediate from the first turn of the key the car was back!!
Took it around the block to warm it up, drives awsome on stock ecu.
Bit of boost at 0.8bar, awsome!!

Drives better low in the revs to due to that cam being a tooth out before (non fault related). Doesn't have that crazy overlap anymore!!

Absolutely over the moon!!!
4 months of grief and I've finially fixed it!

Thanks to everyone for suggestions and those of you that let me test there sensors, power fc, tom for installing the lower timing belt cover (which turns out it wasn't a timing problem)

now idling at around 36psi, high speed of 42psi.

It was a busted fuel pump that caused me this grief!!!!