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I'm convinced ethanol isn't that bad. Thank you! Some progress today. Engine turns over and feels completely normal. I removed the in-tank pump. It didn't come straight out the bottom like I expected. I unscrewed the metal part from outside the tank and the pump would not fit through the hole. I was able to separate the threaded part from the pump via. the rubber hose. I clipped the wires and pulled the pump out through the top of the tank. I'm going to order an in-tank screen and see if screws right in or maybe that'll tell me if there's a threaded sleeve in there that has to come out.
Thanks for the socket size advice (here and elsewhere - 36mm to pull the in-tank pump.)
Going to need tank strap cradle, too. The part that protects the fuel line is completely rusted out. 928 international has them for $200. Anyone got one laying around?
Early cars had a different size thread for the tank insert - 37mm vs 36mm ? check the size on the part you unscrewed - well done with that, its commonly frozen and breaks the insert loose when given too much torque. You wont need an in tank pump - mine worked fine in temps to 120F with only an external. I have had good results with fuel lines by loading the tank with MMO or Seafoam and bridging the pump relay and leaving it running for hours to try to flush out rubbish, then change the filter. My pump died once and reversed voltage cleared the problem. Get a set of CIS gauges from Roger, you will need them . Dont even think about adjusting the mixture screw until you know the pressures. Best book is Watson on Bosch injection - good trouble shooting section.
jp 83 Euro S AT 57k CIS
I had a surprise home improvement project derail progress for 6 months, but I took some time this week and got it running like an hour ago. i'm pumped!
Here's 7 seconds of terrible video proof (it started getting dark early...)
Roger at 928srus was fantastic with helping me get the correct fuel pump and an in-tank filter and a ton of other parts that are still sitting in boxes. Here's what I did this week to get it started:
1) Windows wouldn't roll up but I wanted the car outside while I messed with fuel. I stupidly broke one switch trying to troubleshoot. It wound up being the relay so I swapped it for the horn relay. 2) Let it sit in the sun outside with fans blowing through it which really helped with the mold smell. 3) Unwired the 80's cell phone. 4) New battery. 5) New 8mm radiator hose from head to the oil blow-by pipe. Roger suggested I bypass the goofy pipe but I couldn't easily access the other end where it goes back into the engine so I didn't bypass it. Probably will soon. 6) new in-tank filter, tank-to-pump fuel line, fuel pump. 7) 1.5 gallons of non-ethanol gas, half a bottle of fuel injector cleaner, and sta-bil 8) Jumped the fuel pump relay and let it cycle fuel for a half hour. 9) plugs were still pulled so I did 5 squirts of motor oil in each cylinder then cranked the engine until I got oil pressure and replaced the plugs 9) replaced fuel pump relay, charged the battery. 10) started it on ether - wasn't getting fuel 11) jumped the fuel pump relay and BAM! it ran.
It smoked a bit while burning all the oil I dumped down the cylinders but that cleared up. I only let it get kind of warm (It is for sure low on coolant after that goofy, brittle coolant line broke off in my hand and dumped coolant all over my driveway) I shut it off and was able to restart it.
So yeah, it runs! I need to top off the coolant, figure out what's up with the fuel pump relay, figure out how to replace a vacuum line I broke off that is totally inaccessible without going through half a dozen other equally brittle lines. But! I got a vacuum line kit from roger so I'll for sure wind up doing all of them soon, anyway.
Maybe I'll try to drive it around the neighborhood on Sunday. I'm wary because my last one ran great for 10 miles then something happened with the CIS and it never ran again. My brother's car did the exact same thing last summer - it hasn't moved since. The one thing I'm doing differently this time is non-ethanol fuel. I might be nuts, but I've got an old amc gremlin that has been a constant battle with rubber in the fuel system being eaten up by ethanol (then the gas going bad when it sits.) I found a station an hour away from me with non-ethanol 91 so I drove out there and filled up some cans... Will only run that gas until I know the car is sorted.
Anyway, it runs and that's rad.
Last edited by jdgunn; 10-05-2019 at 11:51 PM.
Reason: removed some ethanol fuel nonsense...
Temporarily swapped the fuel pump relay with the high intensity washer relay. Started right up. After I drove it around the block I noticed all the brake fluid I added was on the ground. Reservoir is leaking at the rubber grommets on top of the master cylinder. Ordering a couple new relays and grommets today.
Been a while! The new master cylinder grommets slowed the leak down but I was still losing fluid somewhere. Finally realized the clutch master was leaking onto the floorboard. Bought a new one based on brake booster diameter and was planning to use the new guts to rebuild the original one in the car. However, the original was a cruddy mess and the internals were different from the new one. So, I ordered an older style master cylinder which was an exact match. I wound up replacing the whole thing which only took me about 5 hours. I did the string trick and my wife could reach in there so she was a huge help.
Took it for a long test drive and learned that I need to bleed the brakes, alternator doesn't seem to be charging, and the fuel line in the rear wheel well started leaking bad. l'm heading out of town and needed a quick fix so I can get it back into the garage. So, I bought 7' of 3/8" fuel line from napa and a couple of clamps. I hacked apart the original line and replaced the rubber section. It didn't leak and I got it into the garage. I'll replace all the lines, next.
Oh, and get this... I had the floor mat sitting on top of the car while I was changing out the master cylinder... I didn't realize the foam was full of brake fluid because apparently I am a moron. My roof now has a nice section where the paint is bubbled up. fantastic! Other than that, it was really great taking that long test drive. I forgot how cool these cars are.
03-23-2019, 06:27 PM
