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    Hard(2nd) Start Issues

    I hate to start another one of these threads but here we go.

    My car started refusing to start on the first crank about 6-8 months ago. I had a fuel pump and regulator on the shelf so I replaced them which resolved the issue but after a few months the car went back to starting hard again. It almost always started on the 2nd key on and ran great so I just lived with it.

    2 weeks ago the car died on me driving home and I was able to coast it to a gas station. Not a convenient time to deal with a tow truck so I got a ride and left it for a few hours. When I returned, the car started fine. Since then I've done some troubleshooting and thrown a few parts at the car but I'd like a sanity check.

    Upon key on the fuel pump runs. It never builds pressure though. I replaced the ekp module/relay thinking that it should maybe run longer but the new part makes no difference. After a few key cycles and start attempts, the car starts and holds 5bar or so at the regulator. Bleeding off fuel with the FP gauge drops the pressure but the car still idles fine. When I shut the car off, pressure immediately goes to zero. I replaced the regulator (im suspicious that the new part was actually new) and the behavior is the same. It seems like the car won't build pressure until it's running.

    It's hard for me to understand how 5 bar could bleed through a leaky injector so quickly but perhaps the car needs injectors? Should I try another regulator? Any other suggestions?

    Thanks in advance.

    #2
    Hella, complete housing, sensor, and pump. I pulled the pump last night and it looked fine. I can check again but iirc it was clamped on both ends. Even so, shouldn't the rail hold pressure after shutting the car off?​

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      #3
      I removed the fuel rail and jumped the pump with both the output line from the regulator and the return line pinched. I've confirmed no leaks at feed to the rail. Injectors can't be the problem. After turning the pump off, pressure still drops to zero. I've seen some mentions of a "check valve" in the pump but after removing and inspecting it, I'm not sure where a check valve would be. It's easy to blow air back through the pump so if there is a valve, it's not doing anything.

      Can anyone confirm if there is a check valve in the pump?

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        #4
        Originally posted by discoelk View Post
        I

        Can anyone confirm if there is a check valve in the pump?
        It should have check valve inside the pump. You can try to add an external cv to the pump output.

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          #5
          Try to crank the starter just before the pump prime cycle end, as when the pump still running it should have 5bar fuel P.
          Last edited by sapote; 05-10-2024, 01:07 PM.

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            #6
            My Hella pump has started doing this too now, it's about a year old.

            Have a read of this,



            I bought some clamps so gonna give it a go on the weekend.

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              #7
              This ended up being a failed check valve inside the pump. Replaced with a DW200 (Walbro 255) and all is good.

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                #8
                Originally posted by discoelk View Post
                This ended up being a failed check valve inside the pump. Replaced with a DW200 (Walbro 255) and all is good.
                How did you test confirm? I pulled my pump out and blew on it and it didn't leak had resistance.

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                  #9
                  Pump housing assembly leaked air out of the pick up when I pressurized the inlet. The check valve fell out of the FP outlet when I removed the pump itself to swap it.

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