Fuel tank/pump/line/filter ..Need serious help

[nixter]

Hey guys, my mechanic is even stumped with this one!

I had my gas tank removed, chemically cleaned of rust and refinished with a plastic coating about 9 months ago. Seems my tank was quite rusted, which was determined when my mechanic removed the fuel filter and rust poured out. At the same time my fuel pump was replaced because it was making noises and then finally died.

Since then the filter has needed replacing twice because more rust was found in the filter. My mechanic put it down to the lines clearing out. Now my pump is making some noise again and low and behold there is rust in my filter AGAIN. My mechanic agrees that this is rediculous but cannot figure out where it's coming from other than the tank. The coating in the tank is red so it's impossible to tell if there's somehow still rust in there, doesn't seem likely though.

Where's this rust coming from??

I really don't want my pump to die again as they ain't cheap! I'm having trouble starting the car as well. Turns over 8 or 9 times on the first attempt then almost starts and dies. Second attempt, springs to life immediately every time. Think it might be pump related?

The rust in the filter is extremely fine. Would this be enough to cause my pump problems? What else could lead my pump to make noise so soon??

My only option at this point seems like a second opinion from a different shop. Ugh.

I'm entertaining ANY opinions/ ideas at this point!

Thanks,

Nik

[nixter]

One more thing, sometimes the engine has a slow pulsing effect, very slightly at idle. Only down and up about 50 rpm or so. Enough that it gets my attention though. Just thought it might be another symptom from the pump.

Nik

[buster73]

Sounds you have dirt/rust in the fuel lines. When you cleaned the tank, did you check the small fuel filter/screen located on the bottom of the tank ? This should prevent dirt and rust to get into the fuel lines. If this filter is damaged (not removed before chemical cleaning ?) or the screen is missing you might end up with debris in the lines. I would guess that flushing the lines and replacing the filter (part # 911 201 141 00) might help. Alternatively you could add a small line filter into the fuel line close to the tank.

Of course it is possible that the tank was not cleaned sufficiently. Most of the rust collects in the round collector bowl around the fuel pick-up and it takes some efforts to get it all out from there. The coating might have not covered all of this area and there is still some rust left.

[nixter]

Thanks bro, yeah the filter in the tank is fine and the lines flow clean and clear. I dunno, this one is a stumper.

Nik

[RoninLB]

could be larger flakes caught in the line breaking up ?

[Joeaksa]

Nik,

Have seen some metal fuel lines rust internally. Had it on my old '72 911 and it stumped me for a long time. Finally figured it out, replaced the line and life was good. Might check this...

Joe A

[nixter]

Hmmm, So how much metal line is there between the tank and the pump? I'mean it has to be the rust screwing up the pump and causing it be be loud right? What else could it be? I'm not too sure of how the mechanics of the pump work but I'm a little confused as to why very fine rust dust would cause it to die. Don't pumps normally have problems when they are forced to work too hard? Could there be some kind of blockage AFTER the fuel filter that puts pressure on the pump only when the filter is on and the car is running normally?

straws... grasping...

Nik

[buster73]

If the rust really comes from the fuel line and flushing won't help, you might indeed have to think about replacing the fuel line. Do you use your car on a regular base ? If it sits for long times, water might collect at the bottom of the tank and get into the lines.

To save your fuel pump in the meantime, you might add a small line filter just before the pump. Adding carb/injector cleaner to the gas should help to purge out loose particles.