Fuel cell project gone bad

[saaristo]

Fuel pump on my 4.3 gxi started to whine already a while ago. Checked the fuel pressure regulator, there black dots visible so diagnosis on the paint problem was put. Ordered myself new pumps and opened up the fuel cell.
The filter side was really good condition


Ok, so I thought must be somewhere else and opened up the cooler side. Indeed, there was a small paint chip missing near the backflow tube.

Naturally I assumed that this is only the beginning and it is on the verge of totally peeling away. But was I wrong, after two days and probably like 15 times with 3 different paint removers this is where I am...

The damn paint just wont come off. So the question is it now too late to turn back and assemble everything as it is, or will it now definitely start to peel away bit by bit?

At the same time, the waterjacket side seems to have pitting just in the places where the O-rings would sit. Will it it hold or will I have leaks?




Any recommendations on how to move on with this?

 

[alldodge]

Fuel flows from the outside to the center. Anything on the outside should be caught by the filter.

As for the pitting, depends what kind of seal is used.

 

[saaristo]

Fuel flows from the outside to the center. Anything on the outside should be caught by the filter.

As for the pitting, depends what kind of seal is used.

Thats the "beauty" of these fuel cells, the paint peeling happens only after the fuel filters.
Regarding seals - ordinary O-rings.

 

[alldodge]

Sorry, was thinking about Merc
Could put a HP inline filter like the ones used on the 525, but would need to flare some new lines. Otherwise use it and hope it doesn't flake anymore.

The O ring should be good enough to seal, it's on the low pressure side. The HP side connects direct to the fuel line

 

[BRICH1260]

When I did mine, I put paint stripper on the inside and got the paint off that way. It worked great.

 

[saaristo]

Tried still one more paint stripper but no luck there. So wire brush on a cordkess drill did the job finally. Anyway, assembled it all back together but havent tested it still. A bit worried on the O-ribgs ability to avoid water and fuel from mixing in the reservoir/cooler due to pitting on both water jacket and fuel side. So theoretically, what could happen if water would be seeping through the seals and mix with fuel?

 

[alldodge]

If water mixed then it would run bad. Get enough water and it doesn't run

 

[BRICH1260]

Tried still one more paint stripper but no luck there. So wire brush on a cordkess drill did the job finally. Anyway, assembled it all back together but havent tested it still. A bit worried on the O-ribgs ability to avoid water and fuel from mixing in the reservoir/cooler due to pitting on both water jacket and fuel side. So theoretically, what could happen if water would be seeping through the seals and mix with fuel?

The stripper I used peeled the paint up quickly and easily. No scraping needed. I think it was made for stripping paint from aluminum though.