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RAV-GT4
Forums Junkie

Toymods member
I supported Toymods

Location:
Rydalmere, NSW
Registered:
May 2002

Re: Andrew's 1999 RAV4/GT-Four Hybrid Project... (22/9/04 - MAJOR pic update)	Mon, 29 November 2004 02:41

Changed over the fuel pump on the weekend. Discarded the old 120L/h RAV4 pump and put in a brand-spanker 250L/h Walbro pump (thanks 1gt48u, it's beer o'clock when I meet you next!). Took a look inside my fuel tank after removing the pump and sender assembly, and it was clean as a whistle. So firstly we can rule out shit fuel or a dirty tank. I was fascinated to see how the fuel tank is baffled - it's like one tank inside another with holes at the bottom to feed fuel from the outer tank inside. Anyway, I had to change over one pump for another and presumably the filter as well, so I assembled everything as was directed by the instructions, until I found out that the GT4 pump firstly wasn't pumping fuel (after everything was put back together), and then after I took a look to see how to correct the problem, it wouldn't fit back into the tank! It was hitting the bottom of the tank and not making the top hatch close by about Œ". Also because the pump wasn't pumping any fuel (the banjo bolt was dry after trying it out), I figured that the wiring might have been reversed polarity. By this time it was 1:00am on Sunday morning, decided to pack it up and try again later that day. About 3:00pm, after sussing out the wiring and making sure polarities WERE correct, I went about trying to figure out why the pump/sender assembly wouldn't fit back into the tank. Eventually I figured out that the fuel filter that goes onto the base of the pump was hitting the bottom of the tank, so I removed it, compared it with the RAV4 filter, and sure enough the difference in height of the plastic mouldings that fit to the filter gause was about Œ". I removed the filter off the RAV4 pump, switched it over onto the GT4 pump and voila! It fit back into the tank with no worries. After Saturday's trial of the fuel pump, when it started up it made the secondary Bosch 500hp pump go silent, which told me either it's getting the right amount of fuel to finally shut it up, or it's not getting any fuel at all. Eventually the car ran out of fuel to the injectors and wouldn't kick over, which prompted me to think that the wiring was reversed. After I confirmed that it wasn't, I tried it again (Sunday afternoon) and it kicked over first go. I left it run for about 5 minutes to make sure it wasn't running out of fuel. However, the external Bosch pump is characteristically noisy. The flow of fuel from the primary pump (Walbro) to the secondary pump (Bosch) has noticeably improved, and now the car doesn't temporarily starve itself in certain situations anymore. It's still comparatively slow for what it is, but hopefully I'll get the ECU worked out soon enough. Also before it was engineered, I felt a little more 'legal' about my car after putting on a Mönza pod shield, which BTW doesn't quite fit the filter! The pod filter is about an inch longer than the shield, but it got passed for engineering anyway. I'm so happy to get those mods out of the way. [Updated on: Mon, 29 November 2004 02:45] [Report message to a moderator]

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