Massive Fuel Delivery Issues - Pump Filter Likely?

[Nitrofgxr6t]

I had this issue twice and when ford looked at it said faulty fuel sender, replaced and all good again. But mines stock so not sure if this helps. When I had it towed by NRMA the guy said common fault on FG Utes. Gauge says half full but tank emtpy, also heard that if you let it run low a lot it happens more often. Once again only on standard systems so not sure with aftermarket in tank pumps.

[camo86T]

Sorted...

Fuel hose again, blew off the pump outlet

When I replaced it earlier on I was a bit scared to tighten up the hose clamp too much in case it cracked the plastic spigot

Tightened the sh*t out of it this time

Positive side, can get the tub liner in and out in record time now

[Nitrofgxr6t]

Sorted...

Fuel hose again, blew off the pump outlet

When I replaced it earlier on I was a bit scared to tighten up the hose clamp too much in case it cracked the plastic spigot

Tightened the sh*t out of it this time

Positive side, can get the tub liner in and out in record time now

Freebie fix... Nice!

[camo86T]

Aaaaaand... this happened again yesterday afternoon

No prior warning but as I took off from work the ute started missing and lurching

Felt exactly like the first time the hose went - would cruise ok but give it a little bit and it started choking.

Managed to limp it home, keeping throttle inputs to absolute smoothest minimum.

From the feel of it you could easily imagine there was a tear in the hose, and as flow increased the tear opened, cutting power.

Fairly long hill in our street, was in first gear by the top of it lol

Pulled the tub liner out

Removable panel makes access easy

Yep there it is

Looks like the clamp has chewed into the hose

But with another look I found a few more damaged areas

Trimmed off the badly damaged piece of hose up the top

Had just enough slack in the hose to get the second most damaged section near the top over the pump module nipple

Yes it did open the tear up but I was able to put the clamp over the top of it

Will do as a temporary measure until I get some more hose, drove about 20km this afternoon without issue, taking it very easy though.

Guess I'll be needing to get this special KPM hose after all

[camo86T]

Update

Ordered the kpm hose on Monday and got it from the post office yesterday afternoon.

The hose looks like a darker version of the original hose, but similarity ends there; it's very stiff, and would have minimal flexibility if not for the convolutions.

Took no time to rip out the liner - again - and get the pump out. One thing I have already drawn up to fabricate soon though, is a ring type spanner to remove/tighten the pump module clamp ring.

Have always used a hammer and large blunt screwdriver to tap it round, but the idea of a swing going wrong and piercing something has always bothered me.

Cut the old hose to get it off easily, and went to try fit up the new hose.

At first go it was obvious that it was going to be forking tight.

Can't remember if the original is similar, but the kpm hose has ends on it that are slightly larger in diameter than the hose itself, so there is no question of what goes where.

But the bloody hose would not go on. Gave KPM a ring to make sure that A, I had the right hose, and B, it didn't need to be heated up slightly to make it fit.

A, correct hose, and B, "nah it should fit comfortably". Okay, have another crack then.

I had planned to knock this job over in next to no time, go home for a shower and change, then drive 90km down to Albion Park for leaf springs, then back to Wollongong for a meeting I had on.

That all went out the window fairly quickly, and I had no other transport from work so this job would have to be finished.

I tried every sort of technique to fit the end on to the first nozzle, 'screwing' it on, short wiggly movements, lubed it with a bit of fuel, but the result was the same; I'd force it on about 5mm until the flared hose end came to the first barb, and that was it, no further. Called KPM again but they were gone for the day, and I knew CMS weren't due back for a few more days.

Tried different hoses, on different nozzles, no difference. Started getting pissed off after a while and threw caution to the wind.

I lit the oxy, and with the weakest flame I could get, held the hose near the end and rotated it in front of the flame, figuring that whatever heat my hand could take, the hose could take a bit more.

Tried it once the end was fairly warm, still no go.

In the end, it took a fair bit of heat and a little bit of inox carefully sprayed onto the outside of the nozzle it was going on.

Finally I had them on except for where the return hose goes into the pot.

went to fit the return hose into the section of the pot where it should go...but nope too short.

sh*t.

I managed to find an offcut of really small stainless tube lying around, and used an offcut of the old hose to go on the end of the nozzle, then fit the tube.

The way it fits now, regardless off fuel or car movement, the tube will stay poking into the pot as it should.

If anyone read to the bottom of this post and is feeling helpful, I'd love to know what the freaking go is with the fitment of this hose...what did I do wrong?

The only thing I can think of is that possibly my ebay-sourced fuel module has slightly larger diameter nozzles on pump and pot...but doubt it.

The other thing is - can anyone see any issue with how I've fit the return hose? Keen to know if I was too fussy, or it's fine or it's bodgy sh*t and should be replaced. Don't know what I'd replace it with, KPM told me they only sell that one length.

Anyone thinking that I was being a bit of a blouse and could've just pushed a bit harder, you can GAGF

Fat arse blister on thumb today

[arronm]

Were both hoses the same length. Are you sure you didn't fit the short hose on the long side

[camo86T]

Correct they were the same length.

From what they told me, they only sell the one length in that hose anyway - 270mm.

But even if they were the wrong length, wouldn't explain why they were an absolute *beep* to get on.

Edited 14/01/16 09:57 PM by camo86T

[Ralph Wiggum]

Boiling water works well to soften the hose and makes it much easier to install.

[camo86T]

Think I may have gone a fair way past that heat-wise but will definitely try it if there's a next time round

Re the dodgy return into the pot - any potential issues you think?

I wasn't too worried about the short section of gates hose, the previous return line was fine with no signs of wear, unlike the supply - guessing it's a combination of ethanol and pressure that does the damage?

[Ralph Wiggum]

Nah I don't see any issue with the hose/ss tube arrangement. When I say boiling water I literally mean boil the hose in it. Softens it up nice after 5 mins or so.

I use the gates E85 (green stripe it think?) hose. but install it slightly differently. I loop the hose to give it the required flex.

It's very important to use the correct lines hose clamps on the fuel hose. The liner stops the clamp biting into the hose. Even more so with hard nylon/plastic fuel hose.