Ok, time for a truck update. Being back on a normal schedule means playing a lot of "catchup" but I had some free time in the garage today and made good use of it.
First up, that fuel pump.
The issue here was I was noticing on very hot days, under lots of load, the fuel pump would act as if it was slurping fuel (think: bog bog bog bog bog catch bog bog bog....), or it wouldn't restart after a stop. I decided to fix it now by replacing the fuel pump and sprung for the most expensive one on RockAuto (a Dlephi unit) in an attempt to ensure that the components that came with it would not be dissolved when submerged in the tank.
Here's how the old one looked coming out:
The first sign that someone had been in there were those orange zip ties... and if this vehicle's history is any indication, someone being in there is NOT going to be a good thing...
Check it out (electrical tape submerged in the tank)
Corrosion on the outside of the connector:
Poorly soldered wires:
Obviously incorrectly sized unit (old unit left, new unit right)
Ok, a lot needs done here but at least I'm learning things and ordered every conceivable component I'd need to do this (fuel sock, a kit that came with all the seals, etc)...
And speaking of "correct components", I really wanted to be sure that whatever I sunk in that tank would be up to the task of not dissolving in the gasoline. For that, I had aviation grade nylon wire, and aviation grade terminal lugs. I've used both in aircraft fuel tanks, and both are rated to be submerged in JP-8 or Jet A-1. Now as to how that holds up with gasoline? well.... I'll just have to take my chances:
I'm also using "environmental heat shrink". I'm not sure it's submersion rated, but it's got that goo that seals everything up when you melt it, so I have some confidence (well, at least I'm more confident in it than I am in electrical tape)
All in all, that should keep us from crossing our streams. I really cant believe I was driving around with an electrical system in that condition, that was submerged in an explosive environment... I swear to Bob that "P.O.S." really means "Previous Owner's Sins"... Everything that's gone wrong with this truck was rooted at the far end of the wrench, but I digress. I got everything back together and stuffed back where it goes. I did have a bit of an issue with the return hard-line as I tried to blow through it but felt a lot of resistance...
Sticking a wire in there and trying to clean things out only served to plug it further. In the end, it took some brake clean and 110psi from the compressor but I blew whatever was in there out. It looks like it was just corrosion (dust that was orange in color).
Next up was the PCV valve. I replaced this because of.... Shoot, it's been a busy month... OH! the oil leak that eventually went away. Ok, so I punched the old one clean through and stuck a filter on the end. The oil leak went away sometime after but I'm not 100% sure that corelation implies causation here as the effects weren't immediate. Still though, I'd like the emissions systems on this thing to be as attached as possible, so on a new one goes.
Except I tore the top of the grommet out of the valve cover during the removal...
No worries though, as I had ordered a new one. I just had to dig the old one out and...
Robert's your father's brother. Op check good.
Let's see what else is still on the list:
Ok, that exhaust leak I can smell but not hear. That tells me it's post muffler. I've got some stainless pipe and a flow-master 50-series that should work for this thing if need be. Hopefully it's just something I can re-hang or patch up to get the exhaust gasses out from under the truck (I'm now convinced that it is the exhaust and not the PCV that's been filling my cabin with fumes when I roll windows down).
The diff oil levels just need to be checked. No reason to suspect any issues there.
Drums out of round: I'm convinced this is rooted in that inspection station "adjusting my brakes". The drums must have overheated, but I don't think I'll get them off to have them turned before I go. I don't have spares for them yet and don't want to risk needing new ones if saaaaay, the machine shop turns them thinner than spec or something (Murphy's law, and all that).
The charcoal canister might actually be a "gas cap" issue. the history on that one is the last gas cap I bought was "universal" in nature and required me to screw it in until it clicked a whole bunch, and then back it out half a turn. If I didn't back it off to open the vent then the charcoal canister would puke fuel everywhere. Today I installed the proper gas cap for this vehicle (vented only to vacuum) and am hoping this thing doesn't puke anymore fuel through its evap system. If it does, then troubleshooting will follow.
The Multifunction Switch is nothing major, but gets to be annoying. What happens is on long drives the high-beams come on by themselves for a few seconds and then click off when I panic and move the switch around. I've had the multifunction switch apart for an issue where the high-beams would turn the headlights completely off when selected. I got everything cleaned and working but maybe I left something loose in there. More to follow, but I will say it is very embarrassing when they flick on and off on the highway as people think I'm flashing to pass (and let's be honest, this thing couldn't pass unless we were heading downhill, with a tailwind, and the other driver let me).
aaaaand the 12v sockets. Total non issue. This is more for an upcoming run to Africa. We want more 12 outlets for nav units, sat phone charging, etc. Probably not something I'm going to get to before Ukraine.
Good times.