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Old 04-02-2013, 01:17 AM   #1
jonney_boy
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Default Car died, Fuel pump?

I have a '06 wrx, 5 speed, 120,000 km, Cobb stage 1, Sti axle back, resonator delete.


The other day I was driving the car, everything was completely normal. Next thing I know, when I went to pull away from a green light, the car lurched really hard. It felt like I step on enough gas and was just ready to stall. Thinking that was what I did, I tried again and problem was still there... pulled over.


Shut the car down, restarted.... everything sounded normal at idle, looked ok. Continued to drive home.


Couple min later, at about 2000rpm the car lost all power. it was sputtering and hardly had enough power to make it down the road. Pulled over again. Turned off the car, and restarted... again it sounded ok.


Once you started moving tho you noticed something was wrong.. stepping on the gas (anything outside of neutral and slowly rolling on the gas) and the car started miss, pop, "fart"... not healthy. Shutting down the car and restarting seemed to fix the problem for a few mins before it returned again.

At this point, I was only 3-4 blocks away from home, got the car home slowly (keeping rpms at about 2500 and jsut "touching" the gas. Pulling over and restarting as needed.... about a block away from home the check engine flashed a few times (3-4?).. then went away... I got home and the the car has been parked since..

The problem was getting worse the more I drove it.. so I parked it as soon as I could. When I got home, at idle, the car was starting to shudder and miss a bit.. I could hear a small exhaust leak coming from under the drivers seat area, I am assuming it's the downpipe / catback gasket..... I will replace this..

Anyhow, got the code reader out today and I got a P0171, P0301, P0303


This leads me to think fuel pump (or something along those lines).

1) What do you guys think? failed pump?
2) How to check if it is really the pump? Reading on here I see there is a test port on the passenger side fuel rail. Does anybody have a writeup for it? (or a how to).
3) Do any shops locally rent the fuel gauge?
4) If I was to replace the pump.... would it be a reliable option to drop in a walbro? And if so, is there a version that was a direct drop in (along with the best place to pick one up).
5) The small Exhaust leak after the cat can't possibly be causing THIS much trouble can it?
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Old 04-02-2013, 01:58 AM   #2
lucky.
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I dont think it's the fuel pump because you're getting misfire on one side of the engine. I would check for vacuum leaks. Vacuum leaks can cause a P0171 code. I would check the right side of the engine for vacuum leaks. hoses, right intake gasket etc.
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Old 04-02-2013, 01:21 PM   #3
Cranker625
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Flashing CEL is never a good sign

Are you the original owner?
What kind of gas have you been using?
When did you do your timing belt?
Fuel pump could be bad (higher chance), but could also be dirty/clogged/faulty injectors (very very slight chance).

1) What do you guys think? failed pump?
You should get 5Zigen to take a look. He'll be able to tell you what's up

2) How to check if it is really the pump? Reading on here I see there is a test port on the passenger side fuel rail. Does anybody have a writeup for it? (or a how to).
No idea

3) Do any shops locally rent the fuel gauge?
No idea

4) If I was to replace the pump.... would it be a reliable option to drop in a walbro? And if so, is there a version that was a direct drop in (along with the best place to pick one up).
I got a Walbro 255LPH complete kit with new filter, hoses, etc for about $120. Best pump for the money IMHO.
Very reliable and can be tuned to maximize duty cycle if you are going that route down the road.
Can be bought at TougeTuning out east. They offer pretty fast shipping.
Can also be bought at Rallysportdirect. Not sure on price though.


5) The small Exhaust leak after the cat can't possibly be causing THIS much trouble can it?
It shouldn't. However, it could be what caused that pop and "fart" sound earlier
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Old 04-02-2013, 03:41 PM   #4
jonney_boy
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Cranker,

I am the original owner,
The car only sees Chevron 94 octane. Granted this is not my daily driver so that tank of fuel was about 3 weeks old
Timing belt is still original as my understanding was it was "due" at 160,000km. Not to mention my sister's car (2.5 TS with the NA) had a timing belt jump a tooth and it make a horriable racket and ran MUCH worse. It also ran poorly ALL the time, not only 1-2 mins after start-up.


I'm going to give it a try first to see if I can fix it at home as I don't think I shoudl be driving the car in it's current state. If I can't figure it out, yes.. having it towed to a shop (or a member's home) would be next on my list.

Starting with the easy things first. I guess I should start by looking for a boost/vacume leak..... followed by checking for fuel pressure
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Old 04-02-2013, 04:53 PM   #5
Cranker625
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My money is on either pump, fuel pressure regulator, filter, fuel lines, pcv, egr
Constant fuel pressure depends on a number of things that can be "reset" after you "turn it off and turn it on again".

ie: When you turn the car off, fuel backs off, sediments in filter settle. Then you turn it on and run for ten mins. Sediments now whirling like a torrent with the active pump pressure, and fuel filter becomes clogged again with flowing sediments. very possible no?

Vacuum leak is a pain to diagnose and pinpoint unless it's very obvious.
And it's not one of those things that go away after you restart the car.

I had the same cylinders misfiring but not leaning out.
Car run like crap, CEL, and then it's fine after I turn it off then on again.
Solution: new sparkplugs, new pcv, new pump, new filter, bad coils.

You are misfiring same cylinders and running a lean condition.
So it could be any one of those things and more.
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Old 04-02-2013, 07:47 PM   #6
KootenayWRX
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Had an episode like this before, same car same setup. Not a full stall thou, Just pop, miss, bad stuff, no cel.

I changed my fuel filter(topped up fuel)and the problem was cured, So I dumped the fluid in the filter into a container. What pored out was water and rusty gas.

Hope your problem is a simple fix, as mine was.
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Old 04-02-2013, 07:51 PM   #7
minifreak
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As mentioned in your other post I'd check on the in tank fuel filter first, it would be nice to use a fuel pressure gauge but probably easier to just pull the fuel pump out and take a look.


You can just see the o-ring got pushed out between the two halves.

I have seen at least 2 failures locally due to this issue :P
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Old 04-03-2013, 03:29 PM   #8
jonney_boy
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Minifreak,

Is that O-ring a subaru part? Plan right now is to get a few of the non-reusable parts ordered in first before I start to pull things appart. I dont' want an open fuel tank in the car while waiting for parts to arrive.

So far I've looked up the gasket for the fuel tank access port.
I'm still looking for the O-ring that you are showing in the picture.
PCV (might as well)
Fuel Filter (again, might as well if i'm already there).

I will also get the car up on a ramp and check the exaust, likely order an exaust gasket too (unless it's a vacume line that is making that exaust leaking sound).


if that does not solve the problem, then i'll close up the hatch again and order in a walbro pump.
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Old 04-03-2013, 07:07 PM   #9
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That's weird! The fuel pump, like electrical stuff is like a light bulb, it either works or it doesn't... but that o-ring issue is strange.
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Old 04-05-2013, 10:00 AM   #10
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Quote:
Originally Posted by clsmooth
That's weird! The fuel pump, like electrical stuff is like a light bulb, it either works or it doesn't... but that o-ring issue is strange.
There are still mechanical components that can fail and it can still turn on or off. Therefore not functioning.
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Old 04-05-2013, 02:46 PM   #11
minifreak
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Quote:
Originally Posted by jonney_boy View Post
Minifreak,

Is that O-ring a subaru part? Plan right now is to get a few of the non-reusable parts ordered in first before I start to pull things appart. I dont' want an open fuel tank in the car while waiting for parts to arrive.
That is not something you can just order separately. As far as I can tell Subaru will only sell the complete fuel pump assembly? But if you can order just the fuel filter it should come assembled with it. The service manual says the in-tank filter is not "serviceable".

What I did was simply took out the filter, by-passed it with a piece of approved fuel line and added an engine bay fuel filter (just order the one for older Impreza).
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Old 04-05-2013, 02:55 PM   #12
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I believe I still have my stock fuel pump from my 07, roughly 90k on it when I swapped for a walbro. Let me know if you want it...
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Old 04-05-2013, 03:19 PM   #13
coupe-a-loop
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Quote:
Originally Posted by minifreak

That is not something you can just order separately. As far as I can tell Subaru will only sell the complete fuel pump assembly? But if you can order just the fuel filter it should come assembled with it. The service manual says the in-tank filter is not "serviceable".

What I did was simply took out the filter, by-passed it with a piece of approved fuel line and added an engine bay fuel filter (just order the one for older Impreza).
If you can find the inside diameter and look into the right suppliers you can get any O-ring you want. Subaru gets them from somehwere right.
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Old 04-10-2013, 09:30 AM   #14
jonney_boy
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Ok, slight update.

Looked around the car for a little bit the other day, Didn't see or hear any leaking vacuum hoses. At least nothing obvious.

I still have a gut feeling it is a fuel problem. I let the car idle for a few mins.. ran great initially and then started stumbling....... turned off and restarted right away... car was hard to start (cranked for a "long" time before it fired).

Went to restart again and let the fuel pump prime first (flip switch to on.... sat for a sec before starting).. car fired right up.. then started to stumble about a min into it.

Check engine light is no longer on... yes the code is still there.

Crawled under the car while it was running... the exhaust leak is not coming from the downpipe / midpipe gasket..... DOH.... I think I got a small hole in the last CAT. I can feel a bit of exaust gasses pulsing out from between the heatshields..... *sigh*..... which bring me to

Any suggestions where to purchase a decent catted downpipe. Looking for something that is Bellmouth, catted (to stop creep), made of stainless, and will bolt up to the stock (sti) exaust.

Was looking at the invida at TougeTuning just because I saw it there while looking for the fuel pump.

WickedXj - THANKS very very much for the offer. After seeing the leak in the downpipe, and with a good chance I might step up to stage 2.... I think I wanted the added security of having a bit more fuel flow "just in case".
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Old 04-10-2013, 03:16 PM   #15
minifreak
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Quote:
Originally Posted by jonney_boy View Post
Ok, slight update.

Looked around the car for a little bit the other day, Didn't see or hear any leaking vacuum hoses. At least nothing obvious.

I still have a gut feeling it is a fuel problem. I let the car idle for a few mins.. ran great initially and then started stumbling....... turned off and restarted right away... car was hard to start (cranked for a "long" time before it fired).

Went to restart again and let the fuel pump prime first (flip switch to on.... sat for a sec before starting).. car fired right up.. then started to stumble about a min into it.

Check engine light is no longer on... yes the code is still there.

Crawled under the car while it was running... the exhaust leak is not coming from the downpipe / midpipe gasket..... DOH.... I think I got a small hole in the last CAT. I can feel a bit of exaust gasses pulsing out from between the heatshields..... *sigh*..... which bring me to

Any suggestions where to purchase a decent catted downpipe. Looking for something that is Bellmouth, catted (to stop creep), made of stainless, and will bolt up to the stock (sti) exaust.

Was looking at the invida at TougeTuning just because I saw it there while looking for the fuel pump.

WickedXj - THANKS very very much for the offer. After seeing the leak in the downpipe, and with a good chance I might step up to stage 2.... I think I wanted the added security of having a bit more fuel flow "just in case".
My car displayed similar symptoms when the fuel filter o-ring blew.

I'd recommend Cobb Catted DP. It is a bit on the pricy side, but meets all your requirements
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Old 04-11-2013, 02:18 AM   #16
jonney_boy
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OK....

Fuel filter, exhaust gasket (turbo/dp), exhaust gasket (dp / midpipe donut), pvc, exhaust spring bolts ordered from SGP.

Walbro 255 + install kit, Catted cobb DP ordered from touge tuning

New spark plugs to be purchased locally (might as well).
Minifreak, when you blew your o-ring.. where did you find a replacement? I checked with Lordco today and they didn't have any o-rings that would work for a fuel application.


Haha, I little bit of a "throw parts at the car" strategy.. but fingers crossed I have covered most of the items
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Old 04-11-2013, 12:34 PM   #17
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You could try calling Greenline Hose & Fittings for the o-ring. They tend to carry a lot of specialized things like that.
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Old 04-11-2013, 05:03 PM   #18
minifreak
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Quote:
Originally Posted by jonney_boy View Post
Minifreak, when you blew your o-ring.. where did you find a replacement? I checked with Lordco today and they didn't have any o-rings that would work for a fuel application.
I simply replaced the in-tank filter with a short length of fuel line and installed an engine bay fuel filter instead.
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Old 04-11-2013, 11:45 PM   #19
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Quote:
Originally Posted by minifreak View Post
I simply replaced the in-tank filter with a short length of fuel line and installed an engine bay fuel filter instead.
Thats the ticket right there
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Old 04-12-2013, 02:12 AM   #20
Drakar
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Not worried about crap gumming up your pump?
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Old 04-12-2013, 01:24 PM   #21
minifreak
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Quote:
Originally Posted by Drakar View Post
Not worried about crap gumming up your pump?
All pre-05 runs engine bay filter, don't think that is an issue. Not to mention it is much easier now to replace the fuel filter vs the in-tank version.
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Old 04-12-2013, 01:35 PM   #22
jonney_boy
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The In-tank filter is AFTER the fuel pump in the '06. The catch is that the spot where the underhood filter sits is "used" by the air pump on the wrx. Unless you decide to ditch the air-pump, there is no place to put the 02-05 underhood filter.


I think the pre-filter (sock) is still there regardless.
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Old 04-12-2013, 02:39 PM   #23
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^ ah ive only worked on 02, but oddly enough the 05 us wrx I have is missing its underhood filter. Not sure whats up there.
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Old 04-28-2013, 04:02 AM   #24
jonney_boy
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ok, update. The problem was the in-tank filter.

The white plastic cap had rotated and popped open on one side, causing the o-ring to bulge out.

Since I had the tank open, I replaced the pump AND the filter and the car runs fine again... YAY..


On a side note, I think this car is still does not like me... hahaha.. went to pull the driver side plugs out (it's due for a change) and the tiny little "buldge" of plastic that allows the plug to catch onto the coil pack broke off..... I didn't even realize that such a small tab could break.. *sigh*...

I tried re-building it with some epoxy tonight, let's see if it works tomorrow.. else.. new coil pack
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Old 01-23-2014, 06:15 PM   #25
magnus70
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Default 06 WRX blowing fuel filter o-rings.

I've had three failures in my tank along these lines.

First I replaced the filter and discovered the upper rubber seal on it was split. Put split one back in and ordered a new one.

Started not starting again. Put in the seal I had purchased.

Blew out the o-ring on the new filter. And bent the tab.

Used old casing and o-ring with new filter element. Ran for while just failed again. It seems to like to fail when I stop part way somewhere like daycare on way home.

I am guessing pressure release valve? I'll probably put the o-ring back again, and get it home then try to get the relief valves. Any ideas where to get them and how bad the price is?
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