You guys will get a kick out of this. I lost all fuel pressure on the fourth lap of my trackday weekend (which would have been 80 laps had it not happened :( Very educational, and humbling, but I figure if it helps even one other person out, I won't feel quite as dumb:
- Installed new Bosch 044 pump, which is much larger than the Walbro – still zero fuel pressure!
- Kinked the fuel pressure regulator return line to see if fuel pressure would increase – still zero.
- Attempted to empty tank by rerouting fuel hose to regulator into a fuel can instead – still no flow.
- Assumed FOD plugging up tank outlet – wrong, full flow at outlet of tank.
- Assumed FOD plugging up 40-micro inlet-side fuel filter – wrong, full flow out of inlet filter.
- Connected outlet of pump directly to fuel can – full flow.
- Disassembled 10-micro outlet-side fuel filter to examine filter element. Filter element was in good condition, but noticed that flow direction arrow on filter housing was opposite how I had it connected (so what, right?).
- Examined filter element for signs of deformation – nothing. The only notable difference was that the spare had a flat end and my filter had a rounded end.
- Installed new filter element, reversed filter plumbing, turned on the pump – full pressure, engine started.
- Couldn’t figure out how the filter element could prevent the car from starting, since it was neither clogged nor collapsed.
- Then, it hit me. Running the filter as I had it, fuel entered the filter on the inside of the element, flowed through it, then down to the other end of the housing, and out. Apparently, the filter element finally developed enough pressure drop for it to be pushed off the end of the inlet housing, hitting the other end of the housing, where fuel pressure deformed the filter element end cap into a perfect plug – and presto, zero fuel flow!
It could have happened anytime, anywhere, and it was a bitter pill that it happened on lap four of a race weekend. My guess is that it was due to the higher than normal fuel flow giving it that extra push; a bitter lesson, that. I don't know how I managed to install the filter backwards; it must have been during final assembly that I either forgot (or never noticed in the first place) that it was direction-sensitive. So I have to take back all the bad things I said about Walbro pumps; there was apparently nothing wrong with mine.
Here's a link to the filter element picture, and keep in mind that the top of it should be flat... http://www.midlana.com/Diaries/Current/my_fuel_filter.JPG