el-dub801 Member 44 Member For: 13y 2m 22d Gender: Male Location: Wollongong Posted 14/03/17 12:17 PM Share Posted 14/03/17 12:17 PM Guys (and girls?) I had an odd occurance happen to me over the weekend with regards to my fuel system... I recently (finally) got my car going again after replacing a set of keys (thanks Ralph Wiggum) and with that came time to start the car after some time being unused. I replaced my in tank pump with a walbro 255 and the bosch 044 that's attached to a PW surge tank as the fuel had gone sh*tty and didnt want to risk it. I also wired up a relay to the 044 as it hadnt been installed when I had the surge tank installed initially. Typical relay wiring configuration as per recommendations. I cranked the car without the 044 hooked up, then plugged in the fuse for the 044 relay and continued to crank until I heard the pump stop and fuel was primed. This is when I experienced the problem - I heard a loud "POP" and a splashing sound under the car, had a look and found fuel splashing out everywhere! Climbed under and checked all lines and fittings - no issues. No hoses split or missing, but what I did find was a crack down the front side of the surge tank where it was welded. I removed the surge tank and fitted the lines back to original configuration and started the car. No problems. My question is... has fitting a higher flowing pump to the tank unit caused this?? I initially thought that I'd wired the relay incorrectly but since refering to instructions ive found on this forum I realised I could have another issue. I wouldnt think that having the smaller capacity pump feeding the tank and the larger capacity pump feeding the rail would be a problem with hydraulic lock. Can anyone offer any assistance?? Link to comment https://www.fordxr6turbo.com/forum/topic/93031-surge-tank-pumps-and-pump-pressure/ Share on other sites More sharing options...
k31th less WHY; more WOT Site Developer 29,579 Member For: 17y 2m 20d Gender: Male Location: Melbourne Posted 14/03/17 12:28 PM Share Posted 14/03/17 12:28 PM sounds like a manufacturing fault, to me. Link to comment https://www.fordxr6turbo.com/forum/topic/93031-surge-tank-pumps-and-pump-pressure/#findComment-1634391 Share on other sites More sharing options...
el-dub801 Member 44 Member For: 13y 2m 22d Gender: Male Location: Wollongong Posted 14/03/17 12:59 PM Author Share Posted 14/03/17 12:59 PM I guess... for it to split the welds and NOT bust a hose is weird. Although I've been using the same set up for a few years with no issues. I just hope the rest of the welds dont fail once I hook it up again. Link to comment https://www.fordxr6turbo.com/forum/topic/93031-surge-tank-pumps-and-pump-pressure/#findComment-1634395 Share on other sites More sharing options...
k31th less WHY; more WOT Site Developer 29,579 Member For: 17y 2m 20d Gender: Male Location: Melbourne Posted 14/03/17 01:01 PM Share Posted 14/03/17 01:01 PM need somebody like @arronm to analyze the metal to figure out where it failed Link to comment https://www.fordxr6turbo.com/forum/topic/93031-surge-tank-pumps-and-pump-pressure/#findComment-1634396 Share on other sites More sharing options...
el-dub801 Member 44 Member For: 13y 2m 22d Gender: Male Location: Wollongong Posted 14/03/17 01:08 PM Author Share Posted 14/03/17 01:08 PM If it goes again I'll be fitting a 460lph and I wont be happy - considering what I initially paid for Link to comment https://www.fordxr6turbo.com/forum/topic/93031-surge-tank-pumps-and-pump-pressure/#findComment-1634397 Share on other sites More sharing options...
arronm Dropping a turd Gold Donating Members 9,520 Member For: 17y 8m 3d Gender: Male Location: Perth Posted 14/03/17 01:33 PM Share Posted 14/03/17 01:33 PM Did you have all the hoses plumbed correctly when the weld failed. Link to comment https://www.fordxr6turbo.com/forum/topic/93031-surge-tank-pumps-and-pump-pressure/#findComment-1634398 Share on other sites More sharing options...
el-dub801 Member 44 Member For: 13y 2m 22d Gender: Male Location: Wollongong Posted 14/03/17 01:38 PM Author Share Posted 14/03/17 01:38 PM Hi arronm Yeah I did. I dug out an installation manual and on PW surge tank, the top two spigots are to and from the fuel tank, the third or bottom spigot is a return from the reg/rail and obviously the supply comes from the poled side of the bosch pump. Link to comment https://www.fordxr6turbo.com/forum/topic/93031-surge-tank-pumps-and-pump-pressure/#findComment-1634399 Share on other sites More sharing options...
Ralph Wiggum Moar Powar Babeh Lifetime Members 19,332 Member For: 19y 9m 6d Gender: Male Location: Perth Posted 15/03/17 12:16 AM Share Posted 15/03/17 12:16 AM Get in touch with Kev from process west. I'm sure he'd like to see the tank that failed. If the weld was sound and the tanks had no external impacts/damage there is no way fuel pressure would be able to cause it to fail. Link to comment https://www.fordxr6turbo.com/forum/topic/93031-surge-tank-pumps-and-pump-pressure/#findComment-1634426 Share on other sites More sharing options...
el-dub801 Member 44 Member For: 13y 2m 22d Gender: Male Location: Wollongong Posted 15/03/17 12:36 AM Author Share Posted 15/03/17 12:36 AM I spoke to Kev over the weekend but I didnt mention the break. I just wanted to clarify the 100% that it was plumbed correctly. Ive had it welded up already and ill hook it up again this weekend. Fingers crossed that its ok. Link to comment https://www.fordxr6turbo.com/forum/topic/93031-surge-tank-pumps-and-pump-pressure/#findComment-1634427 Share on other sites More sharing options...
Ale Member 249 Member For: 13y 10m 4d Posted 15/03/17 12:51 AM Share Posted 15/03/17 12:51 AM amazing , and all this time I figured all this high end, expensive locally made stuff was the ducks guts, imagine if this had been a Pro Flow surge that failed, thread would be 10 pages long. Link to comment https://www.fordxr6turbo.com/forum/topic/93031-surge-tank-pumps-and-pump-pressure/#findComment-1634428 Share on other sites More sharing options...
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