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VanagonEuroVan
Subject:Re: Fuel tank problem solving (Almost)
From:Cunegonde
Date:Mon, 26 Mar 2018 13:35:14 -0700

It’s a $2 hose failure.

When I blew CO2 into the supply/pump side spigot, all I heard was a whooshing noise. Not gurgling, similar to fish tank aerator bubbling sound. Hmmm, was the intake screen detached from its base and above fuel level? But why does the tank seem empty when I tap on it? I filled it just before the problem started!

Planning to switch intake for return fuel lines in hopes of getting enough fuel flow to start the van, I detached the fuel pressure return line at the driver’s side tank spigot. Hose comes off in my hand as soon as I pull on it. A tiny dribble of gas comes out the return line, but nothing on the spigot end. Yep, the the tank’s empty because all the fuel dumped out while I was driving! No wonder the van wouldn’t run. 

I replaced the 8” 7mm ID hose at the return spigot, with new fuel line and  stainless hose clamps. The engine fuel pressure return line is a rigid plastic 7mm OD hose that slips into the 7mm ID connector hose. Is this standard?

I put 5 gallons of gas in the tank. Checked for fuel flow at both spigots. Yes, fuel from both sides. Tried to start car - I can hear the pump running but it doesn’t stop as it should when there’s sufficient fuel pressure. Car turns over but won’t start, presumably no fuel at the engine. I assume the fuel pump is damaged from running dry for too long? 

I detached the pressurized fuel line after the pump. No gush of pressurized fuel as I would expect, just a teaspoon or two from the engine side of the line. 

So next is a replacement fuel pump, or other suggestions?

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