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Deserion Deserion is offline
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Join Date: Jun 2012
Location: Orange Park, FL
Posts: 7
Garage
Question Fuel Pressure/Pump Woes

I'll try to keep this as factual as I can to make potential diagnosis easier.

2004 Boxster 2.7L manual, 90xxx miles.

3/30 - Last drove car, no issues. Parked with 1/4 tank (generally refuel a Shell).

4/1 - Attempted to start car, cranks but did not fire. Tested with Durametric, crank signal reads approximate 162 RPMs during cranking (also displays on tach).

4/6 - Replaced fuel pump with OE part (ordered from Porsche dealer) after determining car has no fuel pressure and pump failed 12v application. Once new pump is installed, car immediately starts and drives normally. Start/stop car multiple times without issue. No debris in tank, no kinked lines. All connectors clicked/tightened correctly.

4/7 - Attempted to start car, cranks but did not fire. Checked fuses, no fault. No fault codes read with Durametric. Changed DME and injector relays, no change.

4/10 - Replaced ignition switch. No change.

4/12 - Replaced fuel pump with another new OE part (from Porsche dealer). Again, car starts up and drives normally without issue. Cycle ignition and works perfectly. Fuel pump is audible upon power-up every few ignition cycles (if cycled rapidly), comes on momentarily then shuts off (not stuck running). No debris in tank, no kinked lines. All connectors clicked/tightened correctly.

4/13 - Attempted to start car, cranks but did not fire. Fuel pump not audible as was roughly 12 hours prior. Car now has a little less than 1/2 tank of fuel (new pump was submerged completely in tank when replaced).

4/15 - Replaced fuel pump relay, no change.

Now, the original fuel pump was disassembled and found to be seized. The first replacement was briefly bench tested and did not turn on (I did not perform the test so I cannot confirm this fully). When ignition on, power is present at sending unit/fuel pump harness plug (will determine exact voltage and amperage today).

Now, is there ANY idea as to why the car will run with a new fuel pump, only to not start 12 hours after the last shutdown? I'm out of ideas on how to diagnose this. Part of me thinks there could be a grounding issue with the pump, also think that it could be a bad DME or crank sensor perhaps (though the car runs immaculately when a new pump is installed).

I haven't been able to find any other real answers on how to solve this, and I'm sure I can't keep having fuel pumps warrantied. Anyone at Pelican HQ with an idea (Wayne)?

Thanks in advance for your assistance. I'm hoping to have my Boxster back on the road soon!
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2004 986 Boxster, Seal Grey/Black
1995 Mercedes-Benz E320 sedan, Moonstone Grey/Grey
Old 04-17-2013, 08:31 AM
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