[s-cars] 95.5 S6A fuel pump check valve failing (now new pump not pumping...)

[McCall, Randy]

Took the list advice and just finished installing a new Bosch fuel pump, with pressure regulator and fuel filter done last week. Started last week with the simpler task and first changed the FPR and filter - no difference in behavior and starts were delayed until fuel pressure built back up after shut downs for more than 10 minutes.  Ran the car nearly out of gas last night and took the plunge and removed the original fuel pump - a string of rubber gasket between the metal fuel pump body and the top plastic were hanging to the side when I removed it, so it was clearly a problem waiting to happen.  

Today I finished the re-install of the pump and added a couple gallons of gas, reconnected the battery, re-installed fuse 17 for the FP relay, and tried to start - nada.  Kept trying for a long time and still no fire.  Cracked open the line to the fuel filter and I got no pressure or signs of fuel at the filter yet.  

I hooked up the new FP identical to old, but used the new Bosch spade connectors and snap in holder - green to the "+" side, brown to the "-" side.  Seated the pump so that both clips were holding it down.  Any ideas or suggestions on diagnosing this new problem?

Thanks,

-Randy


Date: Fri, 20 Jul 2012 22:47:06 +0000
From: "McCall, Randy" <rmccall at nexant.com>
To: "s-car-list at audifans.com" <s-car-list at audifans.com>
Subject: [s-cars] 95.5 S6A fuel pump check valve failing
Message-ID:
	<A8BD3D2436B19441B900A3347FDC164D139986EE at SACEXCH02.nexant.corp>
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I've been driving relatively trouble free for too long apparently!  My 95.5 S6A has recently started showing signs of hard starting - after it shuts down the cranking time has now gone way up.  I at first though perhaps the CPS was going south with some of the first hot weather we've had here in the Willamette valley, but I'm now more convinced that it's the check valve that isn't holding pressure in the fuel lines.  Car runs perfect once it gets fuel, but takes several tries to get it to kick off after I've driven and shut the car off for more than 10-15 minutes.

This is a chipped car with about 175K on the original fuel pump -presumably, as I don't have records of it being changed prior to when I bought it at about 92K.  Probably time to do a FP before it also fails...Any consensus on whether to replace the fuel pump with stock instead of other aftermarket choices, and does a stock FP include a new check valve?  Relaying the FP could be part of the replacement process as well as I see that is often a recommendation.

Thanks,

-Randy