Sylvie Willis
Many vehicles, including the Citroen Picasso, are fitted with an in-tank fuel pump. However, these pumps are prone to clogging and packing up, which can be a hassle to fix. It is possible to convert an in-tank electric fuel pump to an external inline pump by following a few relatively easy steps. This can be done by keeping the existing fuel gauge/sender unit and replacing the faulty in-tank pump with an accessible inline fuel pump. This allows you to bypass the in-tank pump and can give your car more power.
| Characteristics | Values |
|---|---|
| Advantages of an external in-line fuel pump | Easier to access and replace than an in-tank pump |
| May provide more power than the original manufacturer pump | |
| Surge tank bypass can be easily removed and carburetor re-installed | |
| Disadvantages of an external in-line fuel pump | Requires a significantly larger and more powerful pump than an in-tank pump |
| May cause the new pump to work harder and have a shorter life | |
| May not be a long-lasting solution | |
| More expensive than an in-tank pump |
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What You'll Learn
Converting an in-tank electric fuel pump to an external inline pump
Firstly, it is essential to determine the fuel circulation requirements of your vehicle. This can be calculated based on the average brake-specific fuel consumption (BSFC) and the weight of the fuel. It is also important to note that fuel pumps are rated differently, with some measured in gallons per hour (GPH) and others in liters per hour (LPH).
For those seeking to bypass an in-tank fuel pump, there are a few methods that can be considered. One option is to install a remote-mount electric pump, which can be placed outside the tank, such as along the passenger side. This eliminates the need to remove the gas tank, which can be a complex and time-consuming task. However, it is generally recommended to convert to electronic fuel injection when installing an electric fuel pump to ensure compatibility and optimal performance.
Another approach is to utilise a fuel sump conversion kit, such as those offered by Edelbrock and FiTech. These kits function as fuel surge tanks with a high-pressure pump inside. They are mounted near the engine-driven fuel pump, and a fuel hose connects the mechanical pump to the surge tank. The surge tank regulates fuel levels with a float system, and the fuel is then cleaned by a filter before entering the high-pressure fuel pump.
Additionally, when dealing with in-tank electric fuel pumps, it is common for vehicles to have two filters in the tank, which are prone to clogging even when using pump diesel. This can lead to frequent breakdowns and the need for regular cleaning or replacement of the pump.
When converting to an external inline pump, it is crucial to follow safety protocols. Always use axle stands or ramps to support the vehicle instead of relying solely on a hydraulic jack. Additionally, siphon off the majority of the fuel before beginning any work on the fuel system.
In conclusion, converting an in-tank electric fuel pump to an external inline pump can offer several benefits, including easier accessibility and potential performance improvements. However, it is important to consider the specific requirements and challenges associated with your vehicle to ensure a successful conversion.
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External fuel pumps vs in-tank fuel pumps for EFI
There are several factors to consider when deciding between an external fuel pump and an in-tank fuel pump for an EFI system. One key consideration is the ease of installation and maintenance. External fuel pumps are generally easier to service than in-tank fuel pumps, as they are more accessible and do not require removing the fuel tank. This can save time and effort during maintenance or repairs. On the other hand, in-tank fuel pumps are often more challenging to access and may require jacking up the car, draining the fuel, and removing various components to reach the pump.
Another factor to consider is cost. External fuel pumps tend to be more affordable than in-tank fuel pumps, making them a more economical option for those on a budget. However, it is important to note that external pumps may require additional components, such as filters, to ensure the system functions optimally. In-tank fuel pumps, while typically more expensive, often come with the advantage of being cooled by the fuel in the tank, which can extend their lifespan.
The design of the fuel system and the vehicle's performance requirements also play a role in the decision-making process. In-tank fuel pumps are known to be quieter than external pumps, which can be important for those seeking a more comfortable driving experience. Additionally, in-tank pumps are less likely to be damaged in a collision since they are protected by the fuel tank. However, external pumps offer greater flexibility in terms of customisation and can be tailored to meet specific horsepower goals or performance needs.
It is worth noting that both types of fuel pumps can effectively deliver fuel to the engine if plumbed correctly. Ultimately, the decision between an external fuel pump and an in-tank fuel pump depends on factors such as ease of maintenance, cost, noise levels, protection, and customisation options. It is recommended to carefully consider the specific requirements and constraints of the vehicle and the fuel system before making a choice.
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Removing an in-tank fuel pump for an air-pressurized tank
Removing and replacing an in-tank fuel pump can be a complex process, and the specific steps may vary depending on the vehicle. Here is a general guide on how to remove an in-tank fuel pump for an air-pressurized tank, followed by some additional considerations:
First, ensure you are working in a well-ventilated area, preferably outdoors, to minimize the risk of fire and inhalation of harmful fumes. Fuel vapors are highly flammable and toxic, so it is important to take the necessary precautions. Wear safety gear, including safety glasses, gloves, and appropriate clothing to protect yourself from fuel spills and splashes.
Next, locate the fuel tank and drain the fuel into an approved container. If your vehicle has an access panel, you may be able to access the pump without removing the tank. If not, you will need to lift the vehicle and remove the tank. Remember to clean the tank thoroughly during the repair.
Once you have accessed the fuel pump, take note of the fuel line connections and wiring before removing the old pump. Remove all connections, turn the large lock nut to free the old pump, and pull it out. You may need to unscrew a plastic collar that holds the fuel pump in place. This typically unscrews in an anti-clockwise direction.
If you are replacing the in-tank fuel pump with an external inline pump, you will need to cut through the main fuel pipe and fuel pump wires. You can then install the new external pump by connecting it to your battery terminals, ensuring positive connects to positive and earth to negative. Secure a length of tubing to the pump and insert it into the tank.
Finally, reinstall the fuel tank and reconnect the wire connectors and fuel lines. Partially fill the tank and run the vehicle to inspect for any leaks. Remember to replace the fuel filter to ensure your new pump runs smoothly.
Some additional considerations:
- It is important to relieve the fuel system pressure before beginning any work. This can be done by running the engine and pulling the fuel pump relay, or by pressing the Schrader valve on the pressure line to release the fuel spray.
- When removing the fuel tank, use a jack to support it and lower it safely.
- Keep in mind that some fuel pumps require parts to be transferred from the old unit to the new one.
- Always refer to the instructions specific to your vehicle for the most accurate information.
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Using an in-line fuel pump without removing the tank pump
It is possible to use an in-line fuel pump without removing the tank pump, but it may not always work. This method can be used to save time and effort in certain situations, such as when the fuel tank is difficult to access.
Some people have reported success in bypassing the in-tank pump by leaving the old pump in the tank, unplugged, and installing an in-line pump. However, others have stated that this method caused their vehicle to starve for fuel. It is important to note that attempting to cut corners by leaving the old pump in the tank may cause issues in the future.
To bypass the in-tank pump, you will need to siphon off the majority of the fuel from the tank. If you are using a new external pump, you can connect it to your battery terminals by running two wires and securing a length of tubing to the pump, which is then inserted into the tank. This method can also be used to transfer fuel to separate containers for storage.
For specific vehicles, such as the Citroen Picasso, additional steps may be required. These include removing the exhaust heat shield, hand brake cables, filler hose, pipes, and cables, as well as unscrewing the plastic collar that holds the fuel pump in place. It is recommended to refer to vehicle-specific instructions for a successful conversion.
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Bypassing the in-tank fuel pump
Another method to bypass the in-tank fuel pump is to convert it to an external inline pump. This involves removing the old pump, which may require jacking up the car, draining the fuel, and removing several components such as the exhaust heat shield, hand brake cables, and filler pipe hose. Once the old pump is removed, a new external pump can be installed by cutting through the main fuel pipe and fuel pump wires and securing it with cable ties. This method is reported to work well and is more accessible than the in-tank pump.
It is important to note that bypassing the in-tank fuel pump may cause problems with fuel delivery, and it is generally recommended to remove the intake pump and replace it rather than cutting corners. Additionally, it is crucial to prioritize safety when working on a vehicle, especially when dealing with fuel and electrical components. Always refer to the manufacturer's instructions and seek professional help if needed.
Some vehicles, like the Citroen Picasso, are fitted with an in-tank fuel pump that is prone to failure, especially when running waste vegetable oil mixes or biofuel. These pumps often have two filters that are prone to clogging, even when using pump diesel. In such cases, bypassing the in-tank fuel pump and installing an external inline pump can be a viable solution to improve the vehicle's performance.
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Frequently asked questions
Yes, it is possible to bypass the in-tank pump and install an external in-line fuel pump. However, it is important to note that the power line should be protected.
To convert an in-tank electric fuel pump to an external in-line pump, you can follow these steps: first, siphon out the tank. Then, install a proper fuel pressure regulator and plumb a large delivery fuel line. Create a return system using the original fuel line by installing a return bung in the stock-sending unit.
External in-line fuel pumps are more accessible and can provide more power than the original manufacturer pump. They are also useful as an emergency pump.
Externally mounted fuel pumps may not have the same capacity as in-tank pumps, and they are pull pumps, whereas in-tank pumps are push pumps.
Yes, it is possible to use an external fuel pump with an EFI. The bypass is built inside the surge tank.
