Sorry i wasnt clear. Yes, except the injectors, pump and rewire my fuel system is completely stock.

 

Do you think i should cancel my DW300 order and just run a stock- powered Walbro 255 again? Thats the last setup that ran reliably for me.

 

Lots of people have done just fine with a Walbro 255 on E85. Its only good to about 450 whp though. DW300s seem to be doing fine these days but do not quite have the service experience of the Walbro 255. The DW might support a little more power, but not much, if any, in my experience with an otherwise stock fuel supply system.

 

i owned a pretty nasty 95 talon and i did my research when i owned it.. and i can still guarantee you having proper voltage to the pump is not the problem. hell ive seen evo's with boost a pumps on them getting 14-15 or more volts. im not saying it needs a boost a pump i would simply run the fuel pump re-wire. if the fuel return system is gettin over ran which i doubt that sounds like a bad regulator or it needs an aftermarket one. i had a fuel lab 1:1 rising rate on my talon and never touched it after i set base pressure. but still i say judging by your fuel pump sock you have something in your tank screwing things up... i would clean it out.

and if you plan on running e85 dont run a regular 255 pump its gonna burn up get a pump with internals that the e85 wont destroy.

 

and have you changed the cars fuel filter?

 

if your going back to a single 255 get one like this

http://www.ebay.com/itm/NEW-255LPH-Intank-Fuel-Pump-Install-Kit-Turbine-E85-Walbro-GSS342-Alternative-5-/181202111742?hash=item2a307cccfe&vxp=mtr

 

I have run ONLY E85 for the last year or so. Original OEM regulator here. Do you guys think 30 psi on E85 with 320LPH and 1100s warrants an aftermarket one?

AFAIK Evo fuel filters are the sock thing I just showed in my post that keeps getting really dirty really fast, not the separate canister units like 1G Talons (I think 2G Talons fuel pump/filter are similar to Evos?). This is my 3rd this year so yes.

If you mean the return filter on the passenger side, then no, due the reasons I explained in my previous posts.

I already had a Walbro 255s this year and it failed. Especially uninterested in relatively mysterious no-name ones, even of they work, I'm afgter something proven and reliable after all this mess.

All i know is:

- Car ran fine on a 5 year old Walbro 255, except a slight lean spot that coulkd be tuned around, allegedly caused by a dip in voltage.

- Rewired it, punched relief valve, retuned. Pump died 25 miles later. Thus begins the nightmare downfall into a series of pump failures and 1000 miles of towing. fuel filter was filthy, thought this was the reason for failure.

- Install AEM 50-1000 320 LPH, fresh filter, retune. Pump fails 10 blocks later, then after 30 min "rest" starts again and runs fine for a few hundred miles.

- Soon the car starts developing bucking at WOT, fuel-starvation, then rough idle and smoking symptoms. It was so bad I thought running lean had blown my engine. Pump dies again.

- Install DW300, diagnosis, injector cleaning/flow matching by FIC, and supposed retune by a shop. Runs great for about 100 miles, then pump dies again. Fuel filter sock is dirty already.

Bottom line, except for the slight dip in voltage, the stock-wired, un-punched Walbro was the most reliable setup. Nothing but consistent failures within 200 miles of every new pump since.

- History very strongly supports that the hard wire is the factor that started the pump failures.


- WTF could be causing my fuel filters to get so dirty so fast? Bad E85? A few weeks to a month of sitting breaking down something in the fuel system?

- Aftermarket FPR needed?

 

there should be another fuel filter besides the sock, even on the evo i would hope. and i've never heard of a return filter, why would the return be filtered? surely anything that would make it to a return fuel filter would clog an injector?? the pumps shouldnt be burning up like that, is it possible your fpr or return line is clogged?? dead heading the pump would deffinetly kill it fast. do you ever check your e85 at the pump before filling up?? the e85 content varies between pumps and some have a very low content compared to others... good to check it ahead of time

 

also that pump i posted has a lifetime warranty for 80 bux it could be the last pump you would ever have to buy lol

 

im also wondering if you put that black rubber "blanket" like thing around the fuel pump back when the problems started.... the e85 might of ate that if its not made for it, same with the fuel pump sock i've read that you have to make sure they are e85 compatible.

 

i found this searching the interwebs... it might be from running them pumps not designed for use with e-85

"Black deposits on the filter element are brush material from the pumps. I have done multiple E85 systems and the only time I see filters with black deposits is when there is a dead or dying pump."

 

The Evo fuel filter is integrated into the pump carrier. The entire carrier needs to be replaced if the fuel filter is clogged.

 

Yes, there is in fact some sort of return filter on the passenger side. I've seen diagrams, part #s and statements by Buschur referring to it.

I've never used that insulation sleeve.

Do the brushes actually come into contact with the fuel itself? That sounds dangerous? Directly below that post another guys says:

"I don't think that's the issue. Clearly guy posted he has 600 miles on his new E85 setup and this. So his pumps are dying?

I also saw a few threads on evo forums where guys get new pumps and this **** is still in the filters.
Also my own car was on e85 for two years if not more, not a single problem, same filter. I got the car filled it up twice and there was black goo in the filter..."

What do you mean when you say carrier? The entire plastic assembly that the pump goes into? Besides the "sock" I've been posting, and aforementioned retun filter is there another filter?

 

Yep, its in the pump carrier in that crescent shaped portion. I've cut it open and looked at it - its a cellulose filter. Could be that its badly clogged and dead-heading the pump as boostit5.3 suggested. The car would be running very lean though at WOT.

Yes, the fuel runs right through the pump motor and comes in contact with the brushes and stator. Its like that for all of the popular in-tank pumps.

 

Wow this is complete news to me. In that case I'm sure my filter is jacked, and pretty sure that my socks are indeed being filled with brush particles. time to order a new carrier.

P.S what a stupid ****ing design. Makes me want to build my own system from scratch.