mrslysly
09-20-2009, 04:33 PM
Here is my project (in progress, will be updated as I go with more detailed information, ideas, rejects, etc) in the quest to find a solution to the fuel cutout issue.
WARNING! DISCLAIMER! THIS IS ALL INFORMATION DIRECTLY FROM MY CAR. MAZDA MAY HAVE MADE SLIGHT MODIFICATIONS AND YOUR EQUIPMENT MAY NOT LOOK EXACTLY THE SAME AS MINE.
Many people experience it at 1/4 of a tank. I don't know if they track their car or not. Personally I've experienced fuel cut outs on the stock fuel pump and stock fuel system at 2.5 gallons shy of a full fuel tank on longer left hand sweepers. The only upgrade to my car that would affect cornering performance is 245/40/18 Dunlop Direzza D1 Star Spec tires. And this cut out would only happen if under full or near full throttle. If I lifted or modulated the throttle I would lessen the severity or not experience the fuel cut out. As soon as the car exited the corner I wouldn't experience any cutouts. BUT AT 2.5 GALLONS SHY OF A FULL TANK, that was unacceptable to me.
So my first source was MazdaManiac's DIY http://www.rx8club.com/showthread.php?t=176491&highlight=fuel+pump . I purchased a walbro drop in pump and modified the siphon as per MM's initial directions. I enlarged the siphon ventur to 1/8 inch inner diameter. See pictures from his thread for siphon venturi location. He has since revised his directions and modifying the siphon venturi is no longer needed. READ HIS DIRECTIONS MULTIPLE TIMES BEFORE DOING ANYTHING.
I RECOMMEND PURCHASING THE TOOL FROM NAPA, OR THIS MAY HAPPEN TO YOU! (Napa part #: BK 770-8001 runs $23 bucks.) Here is what my ring looks like.
http://i8.photobucket.com/albums/a11/mrslysly/rx8%20fuel%20pump/IMG_1457Small.jpg
It is hard to see it initially, but all the tabs on the right side of the ring are broken off. The result of using a hammer and brass chisel. $58 lesson (cost of a new ring) learned the hard way.
I use the tool from Napa plus another little nifty tool. A centering punch or anything else that has a tappered point that will fit into the holes in the top of the ring.
http://i8.photobucket.com/albums/a11/mrslysly/rx8%20fuel%20pump/IMG_1468Small.jpg
Place the tool into one of the holes and hold it against the ring removal tool and use it as extra leverage to turn the nut. I found that the universal tool alone flexes to much and this provided the extra torque and leverage to easily remove and install the plastic nut.
While I had the fuel pump assembly out I took a picture of the bottom.
http://i8.photobucket.com/albums/a11/mrslysly/rx8%20fuel%20pump/IMG_1454Small.jpg
Here you can see fuel entrance point (the red rubber cap which acts as a 1-way valve to keep fuel in the bowl but yet allow fuel to flow into the bowl when the bowl's level of fuel is below that of the fuel tank) and one of the exit points for the return from the siphon just to the right of the red cap (which is also the overflow from the Fuel Pressure Regulator). The siphon sits over a nipple in the bottom of the fuel bowl and fuel coming out of the siphon goes into three spots. First, there is a small hole in the side of siphon outlet that sits over the nipple in the fuel bowl so some fuel goes directly back into the fuel bowl. Second, some fuel is shunted out the bottom of the fuel bowl and directly back into the fuel tank. Third, some fuel is sent thru a small galley in the bottom of the fuel bowl to reduce some foaming and then that flows back into the fuel bowl.
(More detailed pictures to come next time the pump comes out, and I am working on a diagram of the fuel pump and siphon system)
http://i8.photobucket.com/albums/a11/mrslysly/rx8%20fuel%20pump/rx8fuelsystem-1.jpg
As you have probably guessed that entrance point (the one and only from the fuel bowl unless fuel is running over the top lip into the fuel bowl) with the red rubber cap is not that large. Might have to look at a way to get more fuel into the bowl. Also the channels or galley in the bottom of the fuel bowl is done to reduce the amount of aeration and foaming in the fuel before it spills over the internal lip back into the fuel bowl where the fuel sock is. The sock itself, besides blocking larger chunks of debris, also acts to stop the pump from creating a vortex, which would cause any aeration in the fuel to form larger bubbles and also helps disperse the air bubbles back into the fuel and break the air bubbles up into smaller ones so there are not large bubbles flowing thru the fuel pump.
Unfortunately, when I modified my siphon venture, I may have gone to far up the siphon tube withe the drill bit and damaged my siphon mechanism. My siphon now is actually a straight discharge tube and dumping fuel back into the right side saddle. Even if I completely block the outlet to the engine my pressure relief cap won't open as all the extra fuel is shunted to the right saddle.
I setup a small test with some water in some buckets to see what the fuel pump and assembly would do. Here is a video.
http://s8.photobucket.com/albums/a11/mrslysly/rx8%20fuel%20pump/?action=view¤t=MVI_1466.flv(I know its not easy to see but the outlet on the top that's suppose to run fuel to the engine is pinched off completely at the other end of the fuel hose and the siphon is running into another bucket right beside the black one. You can see the pressure relief cap never moves or opens.) I did prime the pump with fuel before it was put back into the car.
You can see bubbles coming up from the siphon pickup which means that the siphon tube on the fuel pump assembly is actually pushing fuel into the right saddle instead of drawing it into the left saddle like it was meant to do. This is immediately after hooking up the fuel pump back in the car so the siphon line still has air in it.
http://s8.photobucket.com/albums/a11/mrslysly/rx8%20fuel%20pump/?action=view¤t=MVI_1471.flv (this link takes you to the video showing the bubbles coming up)
The siphon pickup is access via the panel on the right side of the vehicle. It uses the exact same plastic lock nut (union nut as per Mazda's FSM) as the fuel pump.
http://i8.photobucket.com/albums/a11/mrslysly/rx8%20fuel%20pump/IMG_1455Small.jpg
If you notice the cover for the right side saddle has the EXACT same plug port as the fuel pump assembly. Its a perfect fit for the plug on the driver side. Hmmmm.....
The siphon pickup in the right tank is simply a screen mounted to the bottom of the tank and attached to the fuel hose. There is no check valve or any other control, as evident from the air bubbles coming out of it, just a simple fuel line and debris screen.
Once open,
http://i8.photobucket.com/albums/a11/mrslysly/rx8%20fuel%20pump/IMG_1456Small.jpg
it looks like a complete fuel assembly could drop right in! Easy setup for running 2 fuel pumps. Now I know how its so easy for others to do it. If you wanted to keep the fuel sender and use the stock 04-08 fuel pump assembly, the lower basket can be modified to give you clearance, and the connector for the fuel sender is the exact same as the driver side one, so it would plug directly into the lid of the fuel pump assembly and give you easy contact point for power for the pump. HMMMM! Ideas!
Pulled apart a spare siphon.
Here are the guts.
http://i8.photobucket.com/albums/a11/mrslysly/rx8%20fuel%20pump/DSCI0390.jpg
Not the easiest to see but its a rubber stopper with a spring. Once pressure exceeds the springs rate, it will open to let fuel flow out the top of the siphon. WARNING! This next piece of info is NOT the correct procedure. I am leaving it in as a fair warning to others. Learn from my mistake.My solution to plugging this up was just a screw with a rubber washer in the hole that the rubber stopper sits over. Yes that means you have to cut the top of the siphon off. Just have to make sure the screw doesn't protrude into the inlet chamber, which you can check by looking into the inlet tube at the top of the siphon. End of Warning.
The piece that MazdaManiac references for melting together is the plastic disc at the top of the siphon. It holds the spring and rubber stopper in the top of the siphon. This needs to be secured so the extra pressure from the upgraded pump won't push it out of the assembly.
Here is the top view of the hole the rubber stopper sits over after I cut the top piece off the siphon.
http://i8.photobucket.com/albums/a11/mrslysly/rx8%20fuel%20pump/DSCI0391.jpg
Note about fuel cell foam. Inserted 2 blocks of foam into the bridge over the drivetrain tunnel and 1 block into the driver side saddle towards the back of the bridge. Noticed right away that filling the tank takes 5x longer as the foam prevents it from entering the tank freely via the filler port and that it takes a long time to overflow into the passenger saddle. That means its working to prevent slosh. The main problem I discovered is that its almost impossible to get the foam to stay put. Every piece slipped out of place and always ended up pushing the fuel level sender down. Fuel cell foam removed until better method of securing it besides just cramming it into place is found.
More to come as the project continues.
WARNING! DISCLAIMER! THIS IS ALL INFORMATION DIRECTLY FROM MY CAR. MAZDA MAY HAVE MADE SLIGHT MODIFICATIONS AND YOUR EQUIPMENT MAY NOT LOOK EXACTLY THE SAME AS MINE.
Many people experience it at 1/4 of a tank. I don't know if they track their car or not. Personally I've experienced fuel cut outs on the stock fuel pump and stock fuel system at 2.5 gallons shy of a full fuel tank on longer left hand sweepers. The only upgrade to my car that would affect cornering performance is 245/40/18 Dunlop Direzza D1 Star Spec tires. And this cut out would only happen if under full or near full throttle. If I lifted or modulated the throttle I would lessen the severity or not experience the fuel cut out. As soon as the car exited the corner I wouldn't experience any cutouts. BUT AT 2.5 GALLONS SHY OF A FULL TANK, that was unacceptable to me.
So my first source was MazdaManiac's DIY http://www.rx8club.com/showthread.php?t=176491&highlight=fuel+pump . I purchased a walbro drop in pump and modified the siphon as per MM's initial directions. I enlarged the siphon ventur to 1/8 inch inner diameter. See pictures from his thread for siphon venturi location. He has since revised his directions and modifying the siphon venturi is no longer needed. READ HIS DIRECTIONS MULTIPLE TIMES BEFORE DOING ANYTHING.
I RECOMMEND PURCHASING THE TOOL FROM NAPA, OR THIS MAY HAPPEN TO YOU! (Napa part #: BK 770-8001 runs $23 bucks.) Here is what my ring looks like.
http://i8.photobucket.com/albums/a11/mrslysly/rx8%20fuel%20pump/IMG_1457Small.jpg
It is hard to see it initially, but all the tabs on the right side of the ring are broken off. The result of using a hammer and brass chisel. $58 lesson (cost of a new ring) learned the hard way.
I use the tool from Napa plus another little nifty tool. A centering punch or anything else that has a tappered point that will fit into the holes in the top of the ring.
http://i8.photobucket.com/albums/a11/mrslysly/rx8%20fuel%20pump/IMG_1468Small.jpg
Place the tool into one of the holes and hold it against the ring removal tool and use it as extra leverage to turn the nut. I found that the universal tool alone flexes to much and this provided the extra torque and leverage to easily remove and install the plastic nut.
While I had the fuel pump assembly out I took a picture of the bottom.
http://i8.photobucket.com/albums/a11/mrslysly/rx8%20fuel%20pump/IMG_1454Small.jpg
Here you can see fuel entrance point (the red rubber cap which acts as a 1-way valve to keep fuel in the bowl but yet allow fuel to flow into the bowl when the bowl's level of fuel is below that of the fuel tank) and one of the exit points for the return from the siphon just to the right of the red cap (which is also the overflow from the Fuel Pressure Regulator). The siphon sits over a nipple in the bottom of the fuel bowl and fuel coming out of the siphon goes into three spots. First, there is a small hole in the side of siphon outlet that sits over the nipple in the fuel bowl so some fuel goes directly back into the fuel bowl. Second, some fuel is shunted out the bottom of the fuel bowl and directly back into the fuel tank. Third, some fuel is sent thru a small galley in the bottom of the fuel bowl to reduce some foaming and then that flows back into the fuel bowl.
(More detailed pictures to come next time the pump comes out, and I am working on a diagram of the fuel pump and siphon system)
http://i8.photobucket.com/albums/a11/mrslysly/rx8%20fuel%20pump/rx8fuelsystem-1.jpg
As you have probably guessed that entrance point (the one and only from the fuel bowl unless fuel is running over the top lip into the fuel bowl) with the red rubber cap is not that large. Might have to look at a way to get more fuel into the bowl. Also the channels or galley in the bottom of the fuel bowl is done to reduce the amount of aeration and foaming in the fuel before it spills over the internal lip back into the fuel bowl where the fuel sock is. The sock itself, besides blocking larger chunks of debris, also acts to stop the pump from creating a vortex, which would cause any aeration in the fuel to form larger bubbles and also helps disperse the air bubbles back into the fuel and break the air bubbles up into smaller ones so there are not large bubbles flowing thru the fuel pump.
Unfortunately, when I modified my siphon venture, I may have gone to far up the siphon tube withe the drill bit and damaged my siphon mechanism. My siphon now is actually a straight discharge tube and dumping fuel back into the right side saddle. Even if I completely block the outlet to the engine my pressure relief cap won't open as all the extra fuel is shunted to the right saddle.
I setup a small test with some water in some buckets to see what the fuel pump and assembly would do. Here is a video.
http://s8.photobucket.com/albums/a11/mrslysly/rx8%20fuel%20pump/?action=view¤t=MVI_1466.flv(I know its not easy to see but the outlet on the top that's suppose to run fuel to the engine is pinched off completely at the other end of the fuel hose and the siphon is running into another bucket right beside the black one. You can see the pressure relief cap never moves or opens.) I did prime the pump with fuel before it was put back into the car.
You can see bubbles coming up from the siphon pickup which means that the siphon tube on the fuel pump assembly is actually pushing fuel into the right saddle instead of drawing it into the left saddle like it was meant to do. This is immediately after hooking up the fuel pump back in the car so the siphon line still has air in it.
http://s8.photobucket.com/albums/a11/mrslysly/rx8%20fuel%20pump/?action=view¤t=MVI_1471.flv (this link takes you to the video showing the bubbles coming up)
The siphon pickup is access via the panel on the right side of the vehicle. It uses the exact same plastic lock nut (union nut as per Mazda's FSM) as the fuel pump.
http://i8.photobucket.com/albums/a11/mrslysly/rx8%20fuel%20pump/IMG_1455Small.jpg
If you notice the cover for the right side saddle has the EXACT same plug port as the fuel pump assembly. Its a perfect fit for the plug on the driver side. Hmmmm.....
The siphon pickup in the right tank is simply a screen mounted to the bottom of the tank and attached to the fuel hose. There is no check valve or any other control, as evident from the air bubbles coming out of it, just a simple fuel line and debris screen.
Once open,
http://i8.photobucket.com/albums/a11/mrslysly/rx8%20fuel%20pump/IMG_1456Small.jpg
it looks like a complete fuel assembly could drop right in! Easy setup for running 2 fuel pumps. Now I know how its so easy for others to do it. If you wanted to keep the fuel sender and use the stock 04-08 fuel pump assembly, the lower basket can be modified to give you clearance, and the connector for the fuel sender is the exact same as the driver side one, so it would plug directly into the lid of the fuel pump assembly and give you easy contact point for power for the pump. HMMMM! Ideas!
Pulled apart a spare siphon.
Here are the guts.
http://i8.photobucket.com/albums/a11/mrslysly/rx8%20fuel%20pump/DSCI0390.jpg
Not the easiest to see but its a rubber stopper with a spring. Once pressure exceeds the springs rate, it will open to let fuel flow out the top of the siphon. WARNING! This next piece of info is NOT the correct procedure. I am leaving it in as a fair warning to others. Learn from my mistake.My solution to plugging this up was just a screw with a rubber washer in the hole that the rubber stopper sits over. Yes that means you have to cut the top of the siphon off. Just have to make sure the screw doesn't protrude into the inlet chamber, which you can check by looking into the inlet tube at the top of the siphon. End of Warning.
The piece that MazdaManiac references for melting together is the plastic disc at the top of the siphon. It holds the spring and rubber stopper in the top of the siphon. This needs to be secured so the extra pressure from the upgraded pump won't push it out of the assembly.
Here is the top view of the hole the rubber stopper sits over after I cut the top piece off the siphon.
http://i8.photobucket.com/albums/a11/mrslysly/rx8%20fuel%20pump/DSCI0391.jpg
Note about fuel cell foam. Inserted 2 blocks of foam into the bridge over the drivetrain tunnel and 1 block into the driver side saddle towards the back of the bridge. Noticed right away that filling the tank takes 5x longer as the foam prevents it from entering the tank freely via the filler port and that it takes a long time to overflow into the passenger saddle. That means its working to prevent slosh. The main problem I discovered is that its almost impossible to get the foam to stay put. Every piece slipped out of place and always ended up pushing the fuel level sender down. Fuel cell foam removed until better method of securing it besides just cramming it into place is found.
More to come as the project continues.