Author Topic: Delica fuel system overhaul  (Read 4432 times)

Offline Tony

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Delica fuel system overhaul
« on: June 23, 2013, 05:24:16 PM »
The Delica has been a bit lumpy with starting recently, glow plugs seem OK, so I thought I may as well change the fuel filter and was greeted with this:



Lots of little black bits - which you can see trickling down the inside of the filter housing here:



A closer look revealed some of the fuel pipe was melting away - not sure if this is just from bio use or from the acetone I've been adding:



Fortunately I've been meaning to replace the food-grade 8mm braided pipes in the engine bay for a while now as they were delaminating badly, so I'd previous bought a decent length of 8mm nylon pipe instead - it's pretty cheap as it turns out.

I've pulled out all the pipework in the system (some of which turned out to be just 7mm to my surprise - at the tank end) and replaced with the 8mm nylon, right back to the tank. This eliminated a bunch of joints so less to leak.



So here we have 8mm up from the tank, course filter, one way water valve (still working very well), assister facet pump powered off stop solenoid feed, and 10" filter housing tucked next to the rad where it gets nice and toasty for the purposes of melting HMPEs in the winter :)  The final stretch back to the IP itself is marine grade hose, since it'll be hot and vibrating at the pump end.  I know it's good as I've had a stretch of this tube in the system for a while now.

Much happier with the fuel system now - though ideally I'd like to drop the tank and replace the short 7mm section there with 8mm too (it's only about a foot long though so no big deal really).

Liking the nylon, it's see through enough to see the fuel and any bubbles, though a little tough to get over 8mm barbs - heating to 110C with a hot air gun seemed to help with this.  Clips are all 8-10mm type.
« Last Edit: June 23, 2013, 05:53:29 PM by Tony »

Offline Dickjotec

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Re: Delica fuel system overhaul
« Reply #1 on: June 23, 2013, 05:37:06 PM »
Nice job, where did you get the nylon from? I need to replace a stretch before MOT.
Btw my tester gets picky about modified fuel systems, complained about a copper bend in the skoda!
Dick
Bio since 2007  running Delica and Octavia

Offline Tony

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Re: Delica fuel system overhaul
« Reply #2 on: June 23, 2013, 05:45:23 PM »
I think it was this guy Dick:

http://www.ebay.co.uk/itm/METRIC-Flexible-Nylon-Pneumatic-Air-Line-Tubing-Compressed-Airline-Pipe-Tube-UK-/140707070015

10mm x 8mm clear (natural)

£2/meter posted

My MOT tester (council test station) is rather fond of the old truck coming back year after year making funny smells.  He always gives it bit of an amazed look each year that it's actually survived another year.

Here he is:

« Last Edit: June 23, 2013, 05:47:13 PM by Tony »

Offline bradburypizza

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Re: Delica fuel system overhaul
« Reply #3 on: November 18, 2013, 04:52:00 PM »
like it Tony mine was getting a bit down on power so have replaced the fuel filter and what a difference !! went to pull out on the dual carriageway near me after doing it and it started to wheelspin

Offline Julian

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Re: Delica fuel system overhaul
« Reply #4 on: November 18, 2013, 05:05:07 PM »
Nice to see your tester smiling.  Each time I take the Disco in the chap I use just scowls and invites me to go to his compeditor round the corner (could be me or the car having this effect ... more likely both!)
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Offline Tony

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Re: Delica fuel system overhaul
« Reply #5 on: November 18, 2013, 09:53:40 PM »
He's a nice bloke, always happy to chat.  Got talking to him this year as they have a new hydraulic plate system for testing suspension parts, the front car wheels sits on it on the ramp and it moves in two dimensions so they can look at the bushes under stress.  But he's not convinced, prefers the old method of pry bars and levers as he says that gives you a "feel" for grittyness and funny lumps where the hydraulic system does not.  Still, cool bit of kit regardless :)

Poor old girl needed a fair bit of welding this year, rusting front chassis parts.  I've welded some nice thick plates over it through and rebuilt the upper suspension bump stop, no way that's going anywhere for many years (rest of the car will rot around it!)

Offline Julian

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Re: Delica fuel system overhaul
« Reply #6 on: November 18, 2013, 10:09:57 PM »
Disco sailed through last year much to mine and the grumpy examiner's surprise.  Next one is due next month.  Only thing I know is wrong is a tail light which works if you kick it ... wondering wether to fix it or kick it just before the test!
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Offline Head Womble

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Re: Delica fuel system overhaul
« Reply #7 on: November 18, 2013, 10:20:47 PM »
Disco sailed through last year much to mine and the grumpy examiner's surprise.  Next one is due next month.  Only thing I know is wrong is a tail light which works if you kick it ... wondering wether to fix it or kick it just before the test!

I think we all know the answer to that, size 9 every time.
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Offline Julian

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Re: Delica fuel system overhaul
« Reply #8 on: November 18, 2013, 10:58:03 PM »
Disco sailed through last year much to mine and the grumpy examiner's surprise.  Next one is due next month.  Only thing I know is wrong is a tail light which works if you kick it ... wondering wether to fix it or kick it just before the test!

I think we all know the answer to that, size 9 every time.

Yeah, but I've had this before with this grumpy old sod.  I was watching him test the car and he pointed out a light which wasn't working.  I slapped the wing and it sprung into life, but he wouldn't accept my "repair".  Luckily it failed on other things so it wasn't really an issue, but if it was just the light I'd have kicked up a fuss.
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