[Scales]

hmm sounds like a plan. ill make some calls to find an o-ring joint in TSV

[royce]

Scales wrote:

the filter is the little teabag thing. looks pretty useless.
I might buy a new one anyway as it would protect the pump and put an inline in the engine bay...

Sure? every in tank EFI pump in teh world has a strainer like that, I would of thought the filter would be on the pressure side like the rest

[Scales]

nope. no filter at all besides that strainer. awesome huh?

[royce]

So whats all the plastic shit between the pump outlet and where the fuel line hooks up do?

[Scales]

just that.... plastic shit.

theres a pressure relief thing in there also.


I just went to a local seal supplier store here, had to order some fuel resistant o-rings from brissy, should be here tomorrow, so ill fit it then. Got some non-resistant ones, but i cant be assed putting it all together just for one night.

O ring size is 4x9 (maybe 9x4 cant remember) if anyone needs em.

[Moag]

Yep like royce said

[royce]

I knew it!

I would extract whatever filter stuff is in there and fit a filter outside the tank

[Scales]

well you cant get into it as far as i can see

[steak_knife]

Scales wrote:

well you cant get into it as far as i can see

This say's you can....

Moag wrote:

:P Yep like royce said

Your problem is the split grommet, but I'd put money on the filter being a lil full to, no point putting in back in with out either replaceing it or ditching it & fitting an in line.

[steak_knife]

Looking closer, I don't think it will work with out a filter or a bit of pipe in it's place...

[Scales]

steak_knife wrote:

This say's you can....

holding it in my hands and seeing it says i cant see a way to......

[stockman]

look harder!

[steak_knife]

Ok!!!!

[Scales]

ill look harder tomorrow. had enough of this car for the moment. beer o clock

edit: sorry for sounding bitchy, just want to get this bastard fixed. havent even looked at the cape york pics yet.

[89_tintop]

WI haven't played with a jimny intank fuel filter yet .. But I have replaced a few on other makes and models.

There is no way to remove the "filter" without damaging the housing. It is all part of the housing. A few that I have pulled apart had a dessicant bag set up (a sock bag with something in it that is the filter) others were made from like a material similar to air filters. Both set up I had to "damage" the housing to remove. This is because if how the fuel runs through the whole thing.. It is because the filter is under pressure and a sealed unit and you have to unseal it to get it out.

Looks like you have found the problem there with the o'ring.. If it was me I would replace the pump anyway. first is because you need to replace the oring and you get a new one with it.. second is becuase I would be damned if I would be pulling the tank out again. Especially considering how cheap they are. At worst case if it was just the seal you would have a spare pump.

[Scales]

well as much as id like to blast 80-150 beans on a new pump for the awesomeness of a new $2 piece of rubber. this is my current solution.


pick the difference. one of these is the original grommet/seal the other is some orings.


these o-rings are the non-fuel resistant ones i picked up for sizing purposes (70 cents each), the proper u-beaut ones are coming tomorrow.

not to worried about dropping the tank now, ive replaced all the rusty bolts on the exhaust with some new ones with anti-seize and its the 2nd time ive dropped the tank in as many weeks so im kinda getting used to the technique. the only hard part is getting the connectors off the fuel tank. Suzuki has a "special tool" they use, but i used a piece of plastic from an old cd spindle to do the job. an ice cream lid would have worked better. but i havent had ice cream for years.

ill take some more thorough photos of the pump assy tomorrow when i hook into it some more.

oh by the way, check out the sealing method used on suzi-stores fuel pump..... looks like an o-ring to me.

[Moag]

I can feel an important fuel filter mod coming on

Might involve a drill, soldering iron, a hammer, some similar plastic and a Z200 mounted outside the tank. Oh and some more beer

Some inspiration !!!

[Scales]

wow, that guy is crazy... or good? im not sure.
either way, im not really sure how to tackle this phantom filter, if it does exist. i rekon i might just proceed with the o-ring stack as i said earlier and get this bastard running, then i can stop worrying about it and finally get to the heavy task of cleaning the half inch of bulldust thats all over it.
if the filter does exist in that assembly, tis no wonder that suzuki wants to charge 300 bux for it, its a pretty crazy piece of plastic.

Oh yeah, and the starter motor is making some badass noises too that i might need some advice with..... it never ends...

[Scales]

sigh
back to the drawing board. got the pump back in with new o-rings, pump runs fine. engine still fucked

when i open the throttle just a crack to let the air in, is when it starts to die.

no fuel return from reg still.

[JrZook]

So you still have low pressure at the fuel rail? Maybe the pump actually was cactus...

[royce]

Did you check for blockages after the pump and before the fuel connection on the tank?
check for blockages along the supply line?

that seal makes me think something is blocking it and the pump jsut pumped it merry heart out till the pressure got too high and popped it

[Scales]

just for shits and gigs i took the fuel reg out and put my finger over it and started the engine. definatley has pressure there. no question about it, and its not dropping in a huge way when i open up the throttle.

oh and line is clear btw.

Im stumped. anyone wanna buy a jimny?

[royce]

remove the hose to the supply side of the fuel rail, ignore the regulator

point that hose into a bucket, turn on pump

fuel should stream out there at a great rate of knots, to the point you cant stop it with your finger over the end

how did you check the line is clear?

[Moag]

Start from the beginning and tick the boxes.
Go through the Inspection table thing.











Think of it as a circuit and look for resistance.

That hidden fuel filter looks likely if fuel pressure isn't to "spec" at fuel rail.

[Scales]

i took the reg out, it squirts out far enough to hit the side of engine bay. luckily i had rags all over it.

blew compressed air down the line.

[royce]

did you check its clear from the pump through the filter to the tank outlet?

the lines need to be clear enough you can breathe through them, dont try but you get the idea.

[Scales]

yeah i blew through it, it has some resistance but not heaps

[JrZook]

Scales wrote:

well the dodgy pressure guage we rigged up (from an old beer regulator) indicated around 20psi. which according to the service manual, should be around 40psi. The pressure drops REALLY rapidly once the pump goes off also.

So whats the rail pressure now with the o rings fitted to the pump?

[Scales]

about the same pressure actually.
20psi. i cant get the fuel up to prime the line and guage also, so could just be 20psi of air getting compressed. keep in mind, the guage is mega dodgy and OLD

[Scales]

just another fyi with that pump assy, looks like the filter is indeed inside the black bit. cant get in there though