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912ULS, no return line, Kitfox model 5. Facet aux fuel pump in series with original mechanical pump.
MGL Xtreme EFIS newly installed with a new 0-7psi sender they recommend, so I have no historical fuel pressure information.

Here's the issue:

When I turn on my pump before engine start, my MGL EFIS shows a nice 3psi stable pressure.

When the engine is in cruise flight, it will make sudden pressure drops down to 2 PSI sometimes
even 1 PSI for a couple seconds then back up to 4 or 5psi. This fluctuation will happen a couple times a minute once it gets going.... my pressure never 'stable' like I wish it was - in my mind no gauge should be swinging that erratically, it doesn't lend any confidence! All else about the motor is great, and fuel flow is pretty consistent so no symptoms there.....

Some reading in the forum here implies this may be a common situation? Is this correct?
If so, it's still disturbing, what do you recommend? Is this a 'problem' or a symptom of
my non-return-line configuration? Would adding the return line and oriface stabilize this
erratic pressure reading? OR do I have something else going on?

Big zinger: should I be concerned? I would like to perfect / smooth out the readings even if it's not a safety concern.

Thanks for your help!
  • Re: Fuel Pressure fluctuations? problems?

    by » 13 years ago


    To answer just the last question, Yes a return line could stabilize your fuel system and all 912's should have the return line, especially with the new fuel pump. With the new fuel pump the return line is an absolute must.
    Does the erratic readings only happen with the electric pump on or is it like that when running just the mechanical pump? For many aircraft there is no need to run both pumps all the time and it can lead to more issues than it will fix. Without a mechanical test gauge in line to check the readings it could possibly be the pressure sender and or electrical ground. These last two should at least be ruled out.

    Roger Lee
    LSRM-A & Rotax Instructor & Rotax IRC
    Tucson, AZ Ryan Airfield (KRYN)
    520-349-7056 Cell


  • Re: Fuel Pressure fluctuations? problems?

    by » 13 years ago


    I understand I 'should' upgrade, but considering I have the old pump i'm putting it off
    for now....

    To answer your quesitons - with aux pump only and no engine running it's smooth (so I feel
    that indicates it's not eletrical or sender problems at this time).

    The swinging fuel pressure happens every few minutes regardless if the aux pump is on
    or off - it seems to have no effect, but my fuel FLOW is constant so I haven't 'worried'
    but I'd like to see pressure readings more stable for peace of mind.

    Could this be a result of the 'pusling' from the mechnical pump? OR, IS MY 10 YEAR OLD FUEL PUMP FAILING causing enough vaccum on the output side to 'pull down' my electric pump's output to 1-2 PSI?
    I don't know the symptoms on a 912 pump failure other than oil leakage these days...

    Thanks!

  • Re: Fuel Pressure fluctuations? problems?

    by » 9 months ago


    Same problem as above; psi variance on Garmin G3X 4.5 to 6.2. Kitfox S7 with 912 ULS; return line installed. Engine RPMs are consistently stable and the measured psi is stable. I’ve read the SBs. Checked for fuel line leaks, loose connections and weak crimps - none. Re-crimped sensor connections - no joy. Considering replacing the Kavlico P4055-15G 0-15 psi sensor, but they’re no longer available. I checked the Garmin Installation Manual Table 21-1 for an alternate, again no joy as Garmin’s 0-15 psi sensor is also not available. 

    What have I missed? Is there an alternative sensor one might suggest? The wife suggested Valium. 


  • Re: Fuel Pressure fluctuations? problems?

    by » 9 months ago


    I see only older threads on this and perhaps that means most people aren’t having problems. 
    Anyway. My Rans S6 with gravity only fuel system has worked flawlessly with the Pierburg Switched to new corona Italy and before I return to service I’m required to test. I have a liquid filled gauge plumbed into the port carb supply. Have run engine 4 times for oil purge, compression test…

    I had replaced all the fuel hoses and installed one of the Golan mini filters. I flow-tested it and an automotive filter at minimum fuel level in tanks. The flow rate was 16 and 20 gallons per hour respectively. I average about 4 flying. With the mini filter, the gauge ran 4 psi for a while before slowly dropping to about 3. The auto filter started at 5 psi stable for several minutes then after getting oil temp up to 200 it dropped slowly in a linear decline as the high rpm run went on, ending about 3 psi or possibly lower. 
    So my question is, does this slow steady drop indicate reduced demand as the flow stabilizes with the carb requirement? Or should the pressure remain more in the midrange. What worries me is the trend seems to be to just get lower and lower pressure. Even though so far it is above 2.2 which means it’s in spec. 
    Quit checking and go fly? Or is this a problem. 


  • Re: Fuel Pressure fluctuations? problems?

    by » 9 months ago


    Hi Julian,

    Where in the fuel delivery system are these filters installed?

    If you are using in line automotive style filters, I would advise they be installed in location where they can be inspected at short regular intervals (daily is best) one filter on each tank supply line. If you have a seperate boost/auxiliary pump line, have one on this as well.

    Do not use sintered bronze or pleated paper filters. Do use gauze filters, that meet the Rotax recommended filtration standards.

    I don't like filters that:

    1. Can not be easily inspected for contaminant build up. 

    2. Have a small area of filter medium that can block too readily.

    3. if you must have a filter that can not be easily inspected, go for one that can be tested/drained before the first flight of the day.


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