Track/kick 1.6L 8V - Popping and sputtering when it's HOT

[JohnnyAirtime]

Originally Posted by JohnnyAirtime

It's IN... and started RIGHT UP!!

Now, to get the rest of everything buttoned up, so I can take it out over Christmas Holiday... and get'er nice and HOT!

Fingers crossed

Good news and bad...

GOOD:
My new power steering works AWESOME!

BAD:
My Sammi still won't run properly.
It did exactly what it did over Thanksgiving holiday (that led me to start this thread in the first place).

Onto the symptoms;
1- First time out, it ran for about 5 miles, and did well.
2- Second time out, it ran for another 5-6 miles... and began to sputter, then died within 100yards.
3- Once or twice, I could get it to barely run... and allow me to limp another mile towards my camp.
... I ended up being towed the last mile or two to my camp.
4- It now won't run at all, unless it's on ether (starting fluid).

And barely runs if at all... backfiring (not out the tailpipe) in the motor like a good hard cough when I try to get it to run (to move it). Because it won't run, I had to push it out of my trailer into my garage (slight uphill). PITA!

I'm going to go get a fuel pressure tester, and test fuel pressure (this next week). Once I test pressure, I'll know more about my dilemma. I'm now leaning towards fuel pump or FPR. It's got to be something simple, that I've not replaced, repaired or tested yet.

[xxx]

why guess.? is the injector dead? sure check pressure,
its a blessing,
anytime, intermittent change to hard fail , IT IS. be happy.
now its easy to find.!!!! and guess, what, when fixed, it dont repeat.
take tools with you, and use them at the failed point.

compression good
spark on all 4. and still timed to where you set it, near 5d, BTDC. , cranking
with the freeze jumper inplace.?
injecto rsquirting Y/N just look at it? its not hidded like 16v, its in the TB.

can be , the classic crank snouth strip out, ignition timing will not go off. with strobe.
in this case,
did you do the FULL TSB on the crank 17mm bolt, ??????
LOOK
is it stripped?
the put it back to 94ft/lbs
the compression will be crap,, 90 is bad, 150 is good,

find the cause when dead.

[JohnnyAirtime]

I bought a $20 fuel pressure tester from Harbor Freight... *connected it up, and as I thought... ZERO psi.

When I undid the small bolt to attach the gauge, I noticed no pressure whatsoever. And this is after we listened for the pump to come on (key on, key off...etc), and I tested voltage at the small white 'pump power' plug. Voltage was good and shut off when the dash relay clicked. (Adding to this)... this is odd, because I usually don't hear the pump from INSIDE the Sammi...but, did hear it a few times out in the desert. At that time, it sounded a bit rough... deeper in tone. Now, I don't hear it at all... but I never have from sitting in the drivers seat.

I pulled the tank (no need to cut an access hole, when it's only 4 bolts and some hose clips..etc) and heavy skidplate, and removed the internal hanger assembly... to find a very well rusted hangar and electrical connections. As I was removing the ground, the tab on the wire broke off (very easily). Maybe the ground was on it's way and caused the 'no pump' issue. *I tested the pump on the bench with 12V, and it spun up. I didn't drop it into any liquid but it didn't seem "smooth" in it's operation. Also, the pickup screen was disgusting. I'm not sure any fuel could pass through it... or if it did, it wasn't going to at a fast pace.

I ordered a full Airtex fuel pump and hangar assembly... *Amazon, for $160 shipped. Local O'Reilly had one but it was $220.00. I'm in no hurry, other then to get this saga behind me... so, by Thursday I should know if the fuel pump/strainer was my (current) running problem. The true test will to be again, take the Sammi out and play off-road and see if we have a similar problem after so many miles of running.

I sure hope not. But I'll update on my findings as I progress.

Here's the pictures of the hangar assembly and fuel pump/strainer;

[xxx]

im so happy you finally found the truth. saves all those guesses and wasted cash
and long walks home.
nice photos showing the ravages of 20 years. of usage
bravo!

cheers !
PS:
if it can hold 30psi, at wot , up hill, its good.
just make sure the FPReg dont stick,. (test with a vac tool at its nipple)
it compensates for altitude.
but can stick, and send pressure to 60psi,.

[JohnnyAirtime]

Originally Posted by xxx

im so happy you finally found the truth. ....

I hope so. BUT, I won't say the problems have been corrected until I take it out and test it. I need to restore my faith and confidence in the Sammi and enjoy it! I'll report back once the pump/hanger come and are installed.

[xxx]

i think they put in a very old kick tank in that sammi
one that sat with for 10 years,what horrible bad fuel. in it... nasty.
the tank will have that bad scale in it, too.
id not run any offroad machine(long walkhome) with scale.
take tank to a good rad shop and get it cleaned like,new
even consider getting it KREEMED. (coated inside)
or a new plated inside tank from Spectra Premium.

what will happen is that junk will slowly flack off ,and keep packing up the filter
and that overloads the pump.
a big hassle... IMO

[JohnnyAirtime]

Originally Posted by xxx

i think they put in a very old kick tank in that sammi
one that sat with for 10 years,what horrible bad fuel. in it... nasty.
the tank will have that bad scale in it, too.
id not run any offroad machine(long walkhome) with scale.
take tank to a good rad shop and get it cleaned like,new
even consider getting it KREEMED. (coated inside)
or a new plated inside tank from Spectra Premium.

what will happen is that junk will slowly flack off ,and keep packing up the filter
and that overloads the pump.
a big hassle... IMO

I think your right about the "old kick tank". And I'm working out a simple, and cheap solution. Electrolysis.

I'm very familiar with the coatings on the inside of the tank, but... I plan on keeping the tank full of fuel at all times. So I don't plan on any coating. The fuel will also be treated with PRI-G to keep it as healthy as possible.

Here's my trash can, and the electrolysis in action;

First few minutes of it being in the barrel


Video of the chemical 'reaction' in process;
P1010996_zps69cac581.mp4 video by johnnyairtime | Photobucket

After only ONE hour;


Simply an amazing process, that works wonders.
Being the pump won't be here until later tonight (the carrier showed up at 7:30pm yesterday - much later then normal), I'll let the process work all day, checking it when the pump gets here. If it's still a tad bit rusty... I'll let the process work overnight (as I'm in no hurry).

[JohnnyAirtime]

Got the new pump and hanger assembly... and I'll have to extend it a little bit;
(amazing how much smaller the pump is, then the older unit - which has a mitsubishi stamp on it)

[xxx]

the only way to fly.
and thanks for photos showing others how easy it is,
i have buddy that etches whole body panels in a huge vat.

the other way is muratic acid,dip
very good, but vary dangerous.
will not touch steel,just rust.

full PPE x 100.

[JohnnyAirtime]

So... I am pretty pissed at myself. No patience led to a broken fuel pump outlet.
(when removing the crimped on fuel line to extend it, I broke the outlet nipple from the fuel pump)

I was going to try and repair it, then I read that JB-Weld breaks down in Ethanol based fuels. *;DARN IT!

...here's my attempt;


Because I realized it won't hold up... and it's just not a good idea, I ordered another one. *And will be sending this one back to the manufacturer, with a note as to my repair (to see if they'll reimburse me - I suspect not). *Bummed... *But, my new one should be here Monday.

I did get the fuel pump hanger assembly lengthened. It only needed a 1.5" to be 10" long, the same length as the assembly I removed. Here's the extended hanger (I used a piece from the old hanger, so it looked factory);


That <error> gave me more time to let the tank soak... I've gone from using Baking Soda (sodium bicarbonate) to turning it into Sodium Carbonate (which is what should have been used all along). It seems to be working better... *Amazing what the top surface of the trash can turns to. And the water, turns somewhat green and icky. I've pulled the tank out a few times and washed it down... seeing it's progress. This soak, is actually bubbling off the sprayed on undercoating from the tank. *I'll touch it back up before putting it back on.

This is about the worse it got with using sodium bicarbonate;
[img width=600 height=450]http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/fuel%20pump/Electrolysis/P1011011_zpsf038ad9a.jpg[/img]

And my donar metal;
*


Using Sodium Carbonate, Here's the top layer;
[img width=600 height=450]http://img.photobucket.com/albums/v298/johnnyairtime/1992%20Samurai/fuel%20pump/Electrolysis/P1011015_zpsff5cdaca.jpg[/img]

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