Spaz
03-31-2011, 09:40 AM
People have been asking for my version of the fuel return so here it is:
So today even though I’m busted up from surgery I decided I would finally finish my fuel system. I had pretty much been done and just awaiting some new parts from Hybrid Racing.
There are a lot of parts involved in doing a full fuel system with return line. This process is not cheap. I’ve seen people spend up to $1k in just their fuel setup. I believe I spent almost $600 myself. Here are some of the parts.. I know I’ll be missing some misc…
After Market Fuel Rail
Fuel Pressure Gauge
Fuel Pressure Regulator
Inline Fuel Filter
Aftermarket Fuel Pump
20ft -6an Fuel Line
3/8” and 5/16” submersible fuel hose
lots of AN fittings (I’ll explain all I used in the DIY steps)
Hose clamps
Zip Ties
Here is what I can remember for the fittings I used...
Straight -6an fittings [4 Total]
-Pump (1x)
-Filter (2x)
-FPR (1X)
45* -6an fittings [2 total]
-Rail (1x)
-FPR (1x)
90* -6an fittings [1 total]
-Rail (1x)
-10an to -6an adapter [2 total]
-Filter (2x)
-8an to -6an adapters [4 total]
-Rail (2x)
-FPR (2x)
90* male to male fitting [1 total]
-pump (1x)
-6an to 3/8th nipple [1 total]
-pump (1x)
-6an plug [1 total]
-FPR (1x)
http://i918.photobucket.com/albums/ad22/typespaz/E85%20Conversion/100_6324.jpg
http://i918.photobucket.com/albums/ad22/typespaz/E85%20Conversion/100_6458.jpg
So lets get started…. The first thing you need to do is install your new fuel pump. I already have a DIY on installing a pump without a return. So start with this DIY to take out the pump and modify the cage
http://forums.clubrsx.com/showthread.php?t=738511
Now lets start the new process!
So I started my new fuel setup today.
Basically I pulled the pump back out. I already had a 255lb pump installed. But now I'm adding a new feed and return setup. So first I dismantled the fuel pump assembly
http://i918.photobucket.com/albums/ad22/typespaz/E85%20Conversion/100_6345.jpg
Then I went and place the nut on the bottom where I will be drilling. You will need this nut. You will also need a 90* male to male 6an fitting to go through the pump. Also I used a 6an to 3/8” barb fitting inside the pump. You can see the fittings in the picture above.
http://i918.photobucket.com/albums/ad22/typespaz/E85%20Conversion/100_6346.jpg
Then I drilled out the hole. I used a blade to clean up the burrs and etc
http://i918.photobucket.com/albums/ad22/typespaz/E85%20Conversion/100_6347.jpg
Now I placed my new fitting threw the hole
http://i918.photobucket.com/albums/ad22/typespaz/E85%20Conversion/100_6348.jpg
http://i918.photobucket.com/albums/ad22/typespaz/E85%20Conversion/100_6349.jpg
Now I attach the barb connector and redo the hoses. I use the stock feed nipple as the return now and the pump goes to the new added barb fitting.
http://i918.photobucket.com/albums/ad22/typespaz/E85%20Conversion/100_6351.jpg
http://i918.photobucket.com/albums/ad22/typespaz/E85%20Conversion/100_6350.jpg
And put the pump back in the tank. Now to start the lines....
First thing I did was mount my inline fuel filter. First I wanted to wrap it in hose so it doesn't vibrate
http://i918.photobucket.com/albums/ad22/typespaz/E85%20Conversion/100_6352.jpg
http://i918.photobucket.com/albums/ad22/typespaz/E85%20Conversion/100_6353.jpg
The using wire I mount it under the car where I wanted it
http://i918.photobucket.com/albums/ad22/typespaz/E85%20Conversion/100_6354.jpg
Now start by putting your line from the pump. Here is the first straight -6an fitting used. Run the hose down to under the car to the fuel filter.
http://i918.photobucket.com/albums/ad22/typespaz/E85%20Conversion/100_6358.jpg
So today even though I’m busted up from surgery I decided I would finally finish my fuel system. I had pretty much been done and just awaiting some new parts from Hybrid Racing.
There are a lot of parts involved in doing a full fuel system with return line. This process is not cheap. I’ve seen people spend up to $1k in just their fuel setup. I believe I spent almost $600 myself. Here are some of the parts.. I know I’ll be missing some misc…
After Market Fuel Rail
Fuel Pressure Gauge
Fuel Pressure Regulator
Inline Fuel Filter
Aftermarket Fuel Pump
20ft -6an Fuel Line
3/8” and 5/16” submersible fuel hose
lots of AN fittings (I’ll explain all I used in the DIY steps)
Hose clamps
Zip Ties
Here is what I can remember for the fittings I used...
Straight -6an fittings [4 Total]
-Pump (1x)
-Filter (2x)
-FPR (1X)
45* -6an fittings [2 total]
-Rail (1x)
-FPR (1x)
90* -6an fittings [1 total]
-Rail (1x)
-10an to -6an adapter [2 total]
-Filter (2x)
-8an to -6an adapters [4 total]
-Rail (2x)
-FPR (2x)
90* male to male fitting [1 total]
-pump (1x)
-6an to 3/8th nipple [1 total]
-pump (1x)
-6an plug [1 total]
-FPR (1x)
http://i918.photobucket.com/albums/ad22/typespaz/E85%20Conversion/100_6324.jpg
http://i918.photobucket.com/albums/ad22/typespaz/E85%20Conversion/100_6458.jpg
So lets get started…. The first thing you need to do is install your new fuel pump. I already have a DIY on installing a pump without a return. So start with this DIY to take out the pump and modify the cage
http://forums.clubrsx.com/showthread.php?t=738511
Now lets start the new process!
So I started my new fuel setup today.
Basically I pulled the pump back out. I already had a 255lb pump installed. But now I'm adding a new feed and return setup. So first I dismantled the fuel pump assembly
http://i918.photobucket.com/albums/ad22/typespaz/E85%20Conversion/100_6345.jpg
Then I went and place the nut on the bottom where I will be drilling. You will need this nut. You will also need a 90* male to male 6an fitting to go through the pump. Also I used a 6an to 3/8” barb fitting inside the pump. You can see the fittings in the picture above.
http://i918.photobucket.com/albums/ad22/typespaz/E85%20Conversion/100_6346.jpg
Then I drilled out the hole. I used a blade to clean up the burrs and etc
http://i918.photobucket.com/albums/ad22/typespaz/E85%20Conversion/100_6347.jpg
Now I placed my new fitting threw the hole
http://i918.photobucket.com/albums/ad22/typespaz/E85%20Conversion/100_6348.jpg
http://i918.photobucket.com/albums/ad22/typespaz/E85%20Conversion/100_6349.jpg
Now I attach the barb connector and redo the hoses. I use the stock feed nipple as the return now and the pump goes to the new added barb fitting.
http://i918.photobucket.com/albums/ad22/typespaz/E85%20Conversion/100_6351.jpg
http://i918.photobucket.com/albums/ad22/typespaz/E85%20Conversion/100_6350.jpg
And put the pump back in the tank. Now to start the lines....
First thing I did was mount my inline fuel filter. First I wanted to wrap it in hose so it doesn't vibrate
http://i918.photobucket.com/albums/ad22/typespaz/E85%20Conversion/100_6352.jpg
http://i918.photobucket.com/albums/ad22/typespaz/E85%20Conversion/100_6353.jpg
The using wire I mount it under the car where I wanted it
http://i918.photobucket.com/albums/ad22/typespaz/E85%20Conversion/100_6354.jpg
Now start by putting your line from the pump. Here is the first straight -6an fitting used. Run the hose down to under the car to the fuel filter.
http://i918.photobucket.com/albums/ad22/typespaz/E85%20Conversion/100_6358.jpg