Sylvie Willis
Installing an in-tank fuel pump in a fuel cell can be a complex process, with many factors to consider. The type of fuel pump, the pressure requirements, and the mounting method are all important aspects to take into account. It is crucial to ensure that the fuel pump is compatible with the fuel cell and that all safety precautions are followed to avoid leaks and other issues. Some people choose to install an in-tank fuel pump to improve the performance of their vehicle, while others may do it to address issues with inline fuel pumps. The process typically involves draining the fuel, disconnecting hoses, and carefully installing the new pump, following the manufacturer's instructions and torque specifications.
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What You'll Learn
Prepare the tank for installation
To prepare the tank for installation, start by draining all the fuel from the car. This can be done by disconnecting a hose from the fuel rail and putting one end into a fuel jug. Disconnect the fuel filler hose from the fuel cell side.
Next, clean out the entire engine bay and cockpit. Protect the new fuel cell from any sharp elements that could rub against it while driving, such as rivet heads and sheet metal edges. Use tape to cover these sharp elements to avoid putting a hole in your new fuel cell. Depending on the fuel cell, it may come with foam that helps reduce the amount of fuel movement as you corner, brake, and accelerate. You will need to cut the foam to fit the surge box in place using a hacksaw blade. The surge box should be positioned at the lowest central point with about an inch of clearance all around.
If you have an external fuel pump and are upgrading to an internal fuel pump, use a brand new gasket and replace the fuel cell cover plate. Loosely thread all the fasteners in place, ensuring that the plastic washers are all in place to prevent leaks. Do not tighten them yet, as you will torque them to the proper spec later. Mark which fitting is which, with a "V" for Vent and "R" for Return.
If you are doing a Gen 3 conversion, you may find it beneficial to slightly clock the fuel filler neck to curve the fuel filler hose. This will make it easier to remove the oil filter when it comes time for oil changes. Use a new gasket if you need to undo the fuel filler neck portion of the closeout plate.
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Ensure the fuel cell is protected from sharp objects
It is important to ensure that the fuel cell is protected from sharp objects. Before installing a fuel cell, you should inspect the area where it will be installed and remove any sharp edges or debris that could damage the cell. When installing the cell, it is important to ensure that it is securely mounted and that all fuel lines are routed away from sharp edges and hot components.
One way to protect the fuel cell from sharp objects is to use steel mounting brackets or straps to secure it in place. These brackets or straps should go around the top, bottom, and sides of the cell, bolting it to the frame or a reinforced floor pan. This will help to ensure that the fuel cell does not shift or move, reducing the risk of it coming into contact with sharp objects.
Another way to protect the fuel cell is to install a secure-fitting fuel cell cap. This will help to prevent vapor leaks and reduce the risk of sparks or explosions. It is also important to replace any worn or missing gaskets to maintain a proper seal.
Additionally, it is recommended to never install or service a fuel cell near an active battery or running engine. By following proper safety precautions, you can reduce the risk of accidents and ensure the protection of the fuel cell from sharp objects or other potential hazards.
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$65.99
Install the fuel pump
Installing a fuel pump in a fuel cell requires careful preparation and a good understanding of the process. Before starting, ensure you have the correct parts and tools, and refer to any instruction manuals or guides provided by the manufacturer.
Firstly, it is important to drain all the fuel from the car. This can be done by disconnecting a hose from the fuel rail and placing one end into a fuel jug. Next, disconnect the fuel filler hose from the fuel cell. This step may vary depending on the specific vehicle, so it is important to refer to the appropriate instructions.
The next step is to prepare the fuel cell for installation. This includes protecting it from any sharp elements that could cause damage during driving, such as rivet heads and sheet metal edges. Tape can be used to cover these sharp areas. Additionally, some fuel cells come with foam that helps to reduce fuel movement during cornering, braking, and acceleration. If necessary, cut the foam to fit the surge box, which should be positioned at the lowest central point with adequate clearance.
Now, we can turn our attention to the fuel pump installation. If you are installing an in-tank fuel pump, refer to the instructions provided by the manufacturer. Ensure that the fuel pump is securely mounted within the fuel cell, following any specific guidelines for your chosen pump.
Once the fuel pump is installed, connect the necessary hoses and lines. Ensure that the hoses are routed correctly and securely fastened to prevent leaks. Pay close attention to the return fuel line, which should be lightly wire-tied to the surge to return unused fuel to the surge box. Keep both lines and wires away from the edge of the filler neck tubing to prevent chafing over time.
Finally, torque the bolts to the manufacturer's specifications. Be careful not to over-tighten the bolts, as this can strip them and damage the fuel cell. Refer to the manufacturer's instructions for the recommended torque settings and follow any specific patterns suggested, such as a star or criss-cross pattern.
It is important to note that this is a general overview, and the specific steps may vary depending on the vehicle and fuel cell being used. Always refer to the manufacturer's instructions and seek guidance from a qualified professional if needed.
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Connect the hoses
To connect the hoses, you will need to determine the type of hose you want to use. The hose can be made of fuel-suitable plastic or rubber and uses push-on fittings. If the outlet on the fuel tank is push-on, you will need to measure the outside diameter of the stub. If the outlet is threaded, check the thread and bore size of the outlet. The same applies to the fuel pump outlet and the outlet on the filter, swirl pot, or fuel rail. If the outlet is a banjo fitting, be sure to check the thread and diameter.
The recommended method to pass through a bulkhead is with a threaded bulkhead fitting. If you are using an external fuel pump, you will need to drill and secure a new pass-through for the electrical connector and then terminate it to the engine harness.
Make sure to tighten the fittings coming out of the cell to prevent leaks. You can use hose clamps to secure the fuel hose so that it will not move and is protected from heat. If you are reusing the cover plate and fittings, block all the holes with plugs and give the plate a good clean.
If your hoses are old and starting to crack, it is a good time to swap them out for a fresh set of AN hoses and fittings.
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Torque the bolts
When installing an in-tank pump in a fuel cell, it is important to torque the bolts correctly to avoid leaks and damage to the fuel cell. Here is a step-by-step guide on how to torque the bolts:
- Begin by lightly snugging the bolts in a crisscross star pattern. This initial step ensures that the bolts are snugly in place before proceeding with the next steps.
- For the fasteners with locating tabs, wait until the fuel cell is in place and the tabs are rotated into the correct position before applying the final torque. It is important not to tighten one side first to avoid pinching and damaging the gasket seal. Aim for an even crush across the entire surface area.
- Torque the bolts according to the manufacturer's recommendations. In some cases, this may involve a two-step process, such as 20 in-lbs followed by 40 in-lbs, as mentioned in the Kanga Motorsports guide.
- Be cautious not to over-torque the bolts, as this can strip them and cause damage to the fuel cell.
- When using a gasket, ensure that the gasket is flat and correctly positioned. The gasket should have a flat side and a ridged side, with the rubber locating tabs going through the corresponding holes in the bottom plate.
- Re-use the gasket if it is in good condition and self-locking, as in the case of the Triumph fuel tank pump kit. However, it is recommended to follow the manufacturer's instructions for your specific fuel cell and pump setup.
- For plastic washers, ensure they are all in place to prevent leaks.
- Mark the fittings with corresponding letters or symbols (e.g., "V" for Vent and "R" for Return) to ensure proper connections during reassembly.
- If you are performing a Gen 3 conversion, consider clocking the fuel filler neck to curve the fuel filler hose, making it easier to access the oil filter for future oil changes.
- When tightening the bolts, follow the recommended torque specifications provided by the manufacturer or a trusted source. In some cases, a torque wrench may be required to achieve the specified torque value.
By following these steps and paying close attention to the manufacturer's recommendations, you can ensure that the bolts are properly torqued when installing an in-tank pump in a fuel cell.
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