Determined to rectify this low fuel spluttering.....

[TheOriginalMrP]

Hi all.

Some of you know that during the early part of this year, I changed my fuel pump top boot. In order to do this I foolishly removed the whole pump out of the bottom boot without remembering the exact seating depth and rotational position of the pump.

It seems simple enough by looking at pictures but since I did the drafted job, the car gets to about quarter of a tank then starts spluttering when revved in neutral.

It's also more difficult to start when fuel is at this level yet anything above that then it starts fine and the spluttering stops.

So back to the drawing board, I have obviously disturbed something, kinked a pipe or put it back together wrong.

I'm tempted to replace everything in the tank yet there is/was nothing wrong with this/these items until I changed this boot.

I found the top banjo was leaking fuel in the summer and rectified that but the general position of reassembly was the same.

So my plan is this... Syphon all fuel out of tank and remove pump and sender ( for more light inside to see what's going on ) and go from there.

After watching Martin's videos it's very likely the question mark hose is kinked but then again the return hard line that curves around the pump wasn't as it looks on the video

Any advice appreciated. I refuse to ignore the issue and just keep the tank more that a quarter full!

Ben

[TheOriginalMrP]

I have been looking at the modern day alternative which incorporates the fuel level sender and fuel pump system all in one which does away with the existing pickup screen and hoses etc, is this the way to go?

There is nothing wrong with my level sender but if one unit replaces everything it will cut down on the unnecessary weight.

Has anyone installed one and how does it perform?

If it's a pile of poo then I will attempt to fix what I've already got.

Ben

[stunned_monkey]

There's no reason you shouldn't be able to get a perfectly serviceable setup with the original components. Check the pickup filter isn't dirty as well (by blowing through it) and follow the video to set the position of the hose once it's in the tank. Also check the pump isn't too low down in the boot causing it to squash the hoses against the tank floor. The return hose is difficult to get wrong as long as it isn't being kinked or squashed.

[Chris Williams]

Quote:Has anyone installed one and how does it perform?

Best to check over on DMCTalk as to views on this, some do seem to be having teething troubles, some think it's great.
Chris

[TheOriginalMrP]

Thanks fellas.

It's hardly rocket science really so as soon as the tank is drained I'm gonna attempt to resolve. I may take some pictures along the way to illustrate my findings.

Ben

[Chris Williams]

If I can do it I have no doubt you can! I did replace all the flexi hoses with new due to the old ones being perished. It's a bit of a fiddle and the hardest part I find is fitting all the rubber pump support/cover while getting the large jubilee clip tight. Martins video is a really great how to and will guide you well!

Chris

[TheOriginalMrP]

Ok so today was quite successful.... I think! First some pictures to show you the position and depth I had my pump fitted.









Of course I sucked the fuel tank dry and mopped the bottom out with clean rags. Last time the car ran she was showing quarter of a tank but I syphoned out a whopping 20 litres. That was divided between my motorbike and my other 2 cars and so I've decided to leave the tank dry while the fuel sender and pump was removed.

Here are some pictures of the pickup inside the tank and the base of tank after I removed the pickup etc.





And it was quite apparent that my pickup filter was stinking dirty with debris and dirt. The hoses didn't look collapsed but I'm going to change them anyway with new spring clips etc. The white plastic parts are a little out of shape but I think they will be fine reused. They seemed to be quite straight when the bolt was holding the retainers in so I won't replace them.

Look at the muck. Do you think this could be partly my sputtering problem?








So now just to order some nice new bits and hope I've seen the end of my spluttering escapades!

Thanks for looking and any advice and comments appreciated!

Ben

[Chris Williams]

Looks like you could have found your problem, At least you can give the tank a proper clean out now and replace/clean everything. So fingers crossed that should cure it
Chris

[stunned_monkey]

CLEAN THAT TANK OUT! Best way is lots of acetone (outside if poss!). Or replace the tank.

[Chris Williams]

Might be worth checking the filler neck as well, in case thats dropping a lot of the crap thats in the bottom of the tank.
Chris

[TheOriginalMrP]

Actually apart from the pickup and filter the rest was surprising clean.

When I mopped up the fuel out of the bottom there was no gunk in the tank at all and the fuel I took out through the syphon was clean too. I think the previous owner ( Spratty ) had already been in the tank and cleaned it out so it should not be totally bogging.

I am hoping what's left in the tank will evaporate, but yes Martin I WILL clean the tank with acetone.

Where can I get some acetone btw?

I think replacing is a bit over the top. Despite the crud that's in the pickup I think the rest on the whole is better than expected!

Cheers fellas.

[Chris P]

eBay for acetone.

[stunned_monkey]

...or fibreglass suppliers

[TheOriginalMrP]

Not cleaned the tank yet but the remainder fuel should have evaporated by now so I shall clean it next week.

I did however get my parts from Ed



Amongst this lot I have New pickup and return hoses, pickup filter and a new stainless hard line that goes through the boot, various clips etc. Basically everything available to do with the pickup has been replaced with new parts.

However I am still not sure where the check valve is situated. It's an 83' model and according to spratty, the check valve is not intergrated in the fuel pump.

I had this discussion with Rich H a few weeks ago but still unsure .

Hope this solves the troubles...

Mr P

[Chris Williams]

Quote:It's an 83' model and according to spratty, the check valve is not intergrated in the fuel pump.

Didn't know that, thought they were all in the pump,
Chris