[ChrisZ]

Oh that's a good subject, isn't it?

I'd like to document what happened, why it happened, and what I did for future reference. Maybe this will help someone in the future.

I've been working on my 87 944S for a few weeks now. Engine will no longer run, it's crazy: I took the intake off and rebuilt it, rebuilt the injectors, I have engine spark, fuel pump on crank, and my noid light shows flashes for the injectors but nothing.

I figured it might be a fuel pressure problem, so after not being able to find my stupid fuel pressure gauge I ordered a $20 cheap o one from Amazon for a one-time use.

Mistake #1: Ordering garbage.

This afternoon I took off the fuel rail cap and ball, and had a towel stuck underneath to catch any dripped fuel and of course the ball when it falls out and gets forever lost in the engine. Happens. Little fuel, looked like some air, no big deal.

Put the adapter and gauge on, turned on the car, cranked it some, could not read gauge, finally got it to where I could see it when cranking. 3.5 bar, right on the line, no problem there. Left the engine in "on" key state.

Mistake #2: Wires were energized.

I then took the gauge off noting that it was leaking because it was crap. Put the ball and cap back on, and cranked it down with a wrench. Slipped with the wrench and caused a spark against metal.

Spilt fuel ignited. FIRE.

First thing I did was shout FIRE, then grabbed the soaked towel and tossed it away from the car. Then noticed that there was still some flames inside the engine. Bad. Walked quickly inside the house, grabbed the kitchen fire extinguisher, came out, flames were still there and this was not good. Hit it twice with the extinguisher, then a third time when it flared up (grease on engine was starting to go I think). Fire was out.

Then walked quickly to the garden hose, turned it on, pulled it onto the driveway, and hosed down the engine bay. Then realized the towel was still on fire and hit that first with the extinguisher, then the water hose.

Probably over in a minute. Good news is it doesn't look like the wiring was damaged yet and the car is not a car be que. If I didn't know where the extingusher was I would have been screwed.

Mistakes made:
1) Buying shit tools. Never again.
2) Not having an extinguisher there while working on fuel components. It's only a little gas and I was seriously complacent. I shouldn't be, back in 1988 I was working on the CIS fuel system on my 84 GTI Rabbit and a line ruptured starting a fire. Fortunately I had an extinguisher right there so it wasn't a big deal.

Smart-ish moves:
Having a towel to catch the fuel. This kept the engine mostly fuel free, so when I yanked it I got the minute to get the extinguisher before things went really bad.

Knowing where the extinguisher was.

Time to get another extinguisher or two.

[worf]

Mistake #0:

*Every time* you close up the fuel system, bypass the fuel pump relay to operate the pump. The only thing “on” is the fuel pump.

Every. Time.

Then, examine the fuel connections you messed with. Then double check the ones you didn’t mess with.

If nothing’s leaking then put the FP relay back in.

I have a 20A toggle switch on two five-foot sections of 10-gauge wire with spade connectors at the ends to plug into the socket. Thus I can stand by the engine bay, toggle the switch and if I see a fuel spray I can toggle it back to off.

Did I mention that you test the fuel system Every Time before you energize anything except the pump?

[ChrisZ]

Good point. Normally I pop open the DME relay and close the top relay (which turns on the pump) to check the fuel system. This disaster happened before starting while closing up the fuel system.

I'm leaving a bad review on Amazon.

[maddog2020]

Mistake #0:

*Every time* you close up the fuel system, bypass the fuel pump relay to operate the pump. The only thing “on” is the fuel pump.

Every. Time.

Then, examine the fuel connections you messed with. Then double check the ones you didn’t mess with.

If nothing’s leaking then put the FP relay back in.

I have a 20A toggle switch on two five-foot sections of 10-gauge wire with spade connectors at the ends to plug into the socket. Thus I can stand by the engine bay, toggle the switch and if I see a fuel spray I can toggle it back to off.

Did I mention that you test the fuel system Every Time before you energize anything except the pump?

I do this, but I also put blue shop towels under every fitting as they change color from light blue to dark blue when they get wet, so its easy to find even the slow drip. I always have a halon extinguisher close by when working on anything fuel related, as well as initial startups after extensive work.

[worf]

I do this, but I also put blue shop towels under every fitting as they change color from light blue to dark blue when they get wet, so its easy to find even the slow drip. I always have a halon extinguisher close by when working on anything fuel related, as well as initial startups after extensive work.

And, your nose is a very good tool when working on the fuel system.