Zed won't start after emptying and cleaning fuel tank

Ok, here's the scenario:

Disconnected both fuel hoses from tank top.
Disconnected electrical connector for pump.
Removed all 6 bolts.
Siphoned ALL remaining fuel out of the tank.
Cleaned interior of tank with clean rag.
Replaced all 6 bolts on top of tank as 5 were cross threaded.
Reconnected pump (double checked)
Reconnected two fuel hoses on tank top.
Put 5 litres of new 98 RON fuel in.
Put ignition in car - no pump priming noise.
Tried to start car - car acted like battery was almost flat.
Tried again - weird symptoms kind of like maybe no fuel and no charge.
Used other car and jumper leads - same symptoms.
Got another 5 litres of 98 RON.
Fuel tank made satisfying rush of air sound when I opened the fuel filler cap, so there is no problem with a leak at the tank top.
But no change - still won't start.

Have I got the two fuel hoses on the tank top mixed up? They are each a different length, so I doubt that is it. I can't think of anything else.

:help:

PS I got huge amounts of photo's so I can do a write-up, but it would be nice to actually have the car running again first.

 

I would be re-checking that the fuel pump has been wired/grounded properly, have you got a circuit tester?

 

what i think is...
may be after u empty the fuel tank..
some air in the fuel pipe..
i mean the part from the fuel pump to the injector..
u know after u emptyed the tank...the petrol in the fuel pipe might leak back to the tank..
i dont know whether it is right..
try to start it a few times..

 

Charge battery, check fuses.....

and put 15 litres of fuel in. You've completely drained the tank, there is ALWAYS some petrol in the bottom that the pump can't access.

 

Big clue there...

Thats what i'd be first concerned about. As someone said before, check the pump is getting power and grounded properly.

MoulaZX

 

doesnt the pump use the fuel as cooling? i would be almost thinking its burnt out.

 

Sounds like the pump is pushing air to the engine(due to insufficient fuel in the tank)as there should be no reason for "swishing sound" other than a partial vacuum in the tank.

 

Thanks all. Yes I do have a multimeter, so I can check the fuses.
I'll have to move some fuel around between containers so I can take a container bigger than the 5 litre one to the service station, but that's no real issue. I'll also leave the filler cap off when I try to start it next time, so their will be minimal vacuum\pressure and that may help get rid of the air in the lines.

FYI I decided after seeing white gunk floating in the fuel that I would not be putting any of it back into the tank, and that a couple of mowers and whipper snippers on my street can get the benefit of 98 RON for a while :thumbup: :zlove:.

 

Ok, the fuse on the drivers side has been checked with my meter and is ok.
I now have 25 litres in the tank.
I used another car to help with battery.

No difference. Still no pump priming noise. The pump power connecter has been checked about 4 times now. Any further guesses\ideas?

 

Well the fuel pump never came out of it's holder thing, and I didn't do anything with the connections other than check to ensure the fuel level sensor was reading the correct ohmage. And the earth is welded or brazed onto the fuel tank lid, so I don't think it's that.

 

Is the pump getting power when attempting start? If not, bypass FPCU.

 

starting to sounds a little like my problem.... are you getting spark?? i know it has nothing to do with fuel, but you never know...

 

That was my next choice. I don't know how to get to it (yet). Looking up tech library now.

Edit: Ok so I can easily bypass the FPCU by earthing the wire wire that leads to the pump.

 

Take hose off fuel filter....

and put in a container. Turn on ignition. If no fuel flows into container, your fuel pump (or controller) is screwed

 

Thanks all. It's all good.

Needed to use another car to give me a jump, and had to bypass the FPCU, and had to crank her a few times to get the fuel through.

FPCU is now back to normal, battery is charging, and she is idling sweet as. Gotta take her for a run to charge the battery and 'knock the cobwebs out'

Watch for the full story as maybe a tech article.

 

So, the final diagnosis is a flat battery ?

 

Sounds like

Sub 10v and ECU will not permit start.

 

Hmmm now I think of it, this is very VERY similar to Awegazm's problem. Aidan, PM me and I'll help you out if you want.

 

well i would say , ,, that 5 liters off fuel will not star the car ,,

the fuel is taken out from the plastic bowl that's sits in the tank,

the fuel you put in the cat goes around the bowl . you need to put more fuel in it to fill up the bowl . then ,

the return line goes straight into the bowl, this is why its never empty ,

you say you got it running , well i would be careful driving to the servo , because you will run out of fuel ,,

get another 10 litters in there ,, your going to need it .

it may start up OK now , but you still need fuel in there ...

your running on fumes .. no good for the engine ..

 

Thanks. I had 25 litres in there when I finally got it running.

It's running fine now.