96 GTI Fuel problem

[OneT]

I'm working on my friends 96 gti. I have everything else fixed except this fuel problem.
The ski will run all day long on reserve but not in the on position ! I took out the fuel selector and cleaned it really good but it was not bad dirty though!
Yes the ski still has the gray lines and the carbs have been cleaned .
I can swap the lines on top of the tank and it runs all day in the on position but not the reserve position. :facepalm:

 

[Bnelson]

With those grey fuel lines your just asking for problems... I would install new lines, re-clean the carbs and selector and then see what happens... As long as those lines are on there it's always gonna be a possibility of an issue... Would also look at the screen on the pickup and make sure it's clean. Unless your somewhere all the fuel is ethanol free?

 

[Coastiejoe]

I'm working on my friends 96 gti. I have everything else fixed except this fuel problem.
The ski will run all day long on reserve but not in the on position ! I took out the fuel selector and cleaned it really good but it was not bad dirty though!
Yes the ski still has the gray lines and the carbs have been cleaned .
I can swap the lines on top of the tank and it runs all day in the on position but not the reserve position. :facepalm:

This is easy...The main fuel line is plugged between the tank and the selector. This justifies why you can swap th elines at the tank and you MUST turn the valve for the ski to run.

Bottom line is, you MUST replace all Grey Tempo lines or you will destroy the engine.
Here is why.... The lines supply the fuel to the engine, right... What else does it supply? The oil,,, Without oil the engine will destroy itself. Even when it does run, I can promise you that you are creating a lean condition, which again means you are providing less oil than what it not only wants, but what it needs.

So change ALL the lines unless you have the desire to change the engine (Don't forget the line between the carbs. And the carbs and filters should be re-cleaned as you are simply letting the green goo get to those items until you change the lines),,,, (Even then, you'd be changing the new engine if you don't replace the lines).

 

[OneT]

both lines are clear !!!!! Can the fuel selector go bad other then being clogged up ? The seals inside of it are still soft and it is all clean !!
I will replace the lines asap !

 

[Coastiejoe]

both lines are clear !!!!! Can the fuel selector go bad other then being clogged up ? The seals inside of it are still soft and it is all clean !!
I will replace the lines asap !

Yes a fuel selector can clog. Happens often. This is why most recommend you replace it rather than clean it. I think it is like 20 bucks. There are plastic and metal versions. Get a metal one.

Tell me this, (I have not had your fuel tank in my hand so I can't answer this question). The lines that go into the top of your tank, are they the NORMAL RUN line and the RESERVE line? If so, then I still think I am right. I know it is your ski, but logic will not change per say.

If the lines are in the normal correct location and the valve is in ON, it wont run. So you swap the lines and it does run. On the same token, on RESERVE it runs fine. This means (assuming the lines you are swapping are the ON and RESERVE line) that no matter what you are on the RESERVE line.

The one thing I do not know is, is the fuel baffle made in such a way that it picks up differently for the ON line and the RESERVE line. If so, then it could easily be the baffle. Someone that has specific knowledge will jump in shortly I hope.

And,,,, because you MUST turn the selector and it runs in either location, I do think you have the selector clean.

Follow me ???

 

[OneT]

Ok
If i put the selector to reserve and the lines are all hooked up per the book it runs fine.
If i put the selector to on and the line are all hooked up per the book it runs until the line runs dry and dies.

Now
If i put the selector to reserve and swap the two lines on the fuel pickup it runs until the line runs dry and dies
If i put the selector to on and swap the two lines on the fuel pickup it it runs fine.

This selector is nice and clean and the seals inside are perfect!
As for the top of the pickup in the tank .... i have return,vent,reserve and on . I guess that is what they are called!
I checked that line coming from the tank to the on side for air leaks and found none!!

I can't see the selector going bad if it is not clogged up in anyway and the seals are like new !!!!

I'm lost on this problem besides i need to change the fuel lines i know !!!!!!

Thank You Coastiejoe for helping me ! :thumbsup:

 

[Coastiejoe]

It isn't your selector, that we know.

It is one of two things. The line or a fitting within the "ON" line is plugged. Or, where the "ON" line connects to the tank, what is below it is plugged. It really can't be anything else based on what you have posted..