Katerina Swanson
Determining the correct fuel line fittings for your vehicle can be a daunting task, but with a little planning, it can be a straightforward process. The fuel line diameter is an important factor to consider, as it can impact the performance of your engine. A larger diameter is generally better, but choosing the correct diameter is crucial. The inside diameter is more important than the outside diameter as it ensures a proper fit and optimal fuel flow to the engine. There are various types of hoses available, such as push-on hoses, which are commonly used in production cars, and hoses with stainless steel over-braids that prevent the escape of fuel vapour. It is important to consider the specific requirements of your vehicle, such as the type of fitting, the size of the outlet, and the thread and bore size, to ensure a safe and efficient fuel system.
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What You'll Learn
The importance of fuel line diameter
The fuel line diameter is a critical aspect of fuel system design, and selecting the appropriate diameter is essential for optimal performance. A larger diameter is generally preferable as it allows for higher fuel flow rates, ensuring the engine receives adequate fuel supply to meet its horsepower requirements. However, it is crucial not to oversize the fuel lines, as this can lead to increased pressurization time, causing potential issues if the pump struggles to maintain pressure during periods of high demand, possibly leading to engine damage.
The correct fuel line diameter is influenced by several factors, including the type of fuel used. For example, when using ethanol or methanol, it is recommended to increase the fuel line size compared to a gasoline-powered system. Ethanol requires approximately 30% more fuel than gasoline to generate equivalent horsepower, while methanol demands double the amount. By selecting a larger diameter, you can ensure an uninterrupted fuel supply to meet the engine's demands.
Another consideration is the return line diameter. The return lines, situated after the regulator, can typically be one size smaller than the feed line. This design consideration aims to maintain optimal fuel pressure and flow while preventing excessive fuel from returning to the tank, which could cause aeration issues.
Additionally, the choice of hose material and fittings plays a role in determining the fuel line diameter. The hose must be compatible with the type of fuel and the operating pressure of the system. Common materials include rubber or plastic, with options for low-pressure carburettor systems or high-pressure fuel injection setups. The fittings must securely connect to the hose, and the bore size of the hose must match the fittings to prevent leaks and ensure proper fuel flow.
In conclusion, the fuel line diameter is a critical aspect of fuel system design, impacting performance, efficiency, and engine health. While a larger diameter is often beneficial, it is crucial to select the correct diameter based on the specific engine requirements, fuel type, and system components. By making informed decisions about fuel line diameter, you can ensure optimal fuel delivery, support horsepower goals, and maintain the overall performance of your vehicle.
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Return lines can be smaller than feed lines
The diameter of a fuel line is critical. While a larger diameter is generally preferable, the correct diameter is determined by the specific application. If the diameter is too small, you won’t be able to support your horsepower goal. Conversely, if the diameter is too large, the lines will take longer to pressurize, potentially leading to engine damage if the pump cannot maintain the pressure.
Return lines, which are the fuel lines after the regulator, can typically be one size smaller than the feed lines. This is because the return lines operate at lower pressure than the feed lines. If the return line has a larger diameter, it may not be able to build up pressure. This is due to the lower pressure requirements, where any return line restriction can cause an increase in fuel pressure.
The specific diameter of the fuel line will depend on the type of fuel being used. For example, ethanol requires 30% more fuel than gasoline to generate the same horsepower, so the fuel line diameter should be one or two sizes larger than the gasoline requirement. Similarly, methanol will require double the amount of fuel compared to gasoline, necessitating a larger fuel line diameter.
When selecting a fuel line, it is important to consider the type of fitting required. The fittings can be threaded or pushed on, and the diameter of the stub or bore must be measured to ensure the correct size is selected. The fittings are also available in different colours, such as red, blue, or black, and can be made of alloy or steel with a plated finish.
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Push-on hoses are cost-effective
Push-on hoses are a cost-effective solution when looking to renew your fuel lines. They are easy to fit in place and can be used on standard parts with no modification. They are also easy to cut to length and are available in a range of internal diameters, including 6mm, 8mm, 10mm, 12mm, 15mm, and 19mm. They can be secured with hose clips or swaged on, and they are suitable for both low-pressure (carburettors) and high-pressure (fuel injection) applications.
While push-on hoses are a cost-effective option, it is important to note that they are not recommended for use inside the car. This is because they allow vapour and fumes to escape, which can make the cockpit an unpleasant place to be. Additionally, if used in long lengths, they will require a lot of supporting clamps to keep them in place due to their flexibility.
Push-on hoses are commonly found in production cars, with 8mm bore being the most common size. Some older, smaller-engined cars with carburettors may use 6mm hoses, while larger-engined cars can use 10mm hoses. Fuel-injected cars typically use 12mm or 15mm hoses from the tank to the pump, depending on the application.
When it comes to fittings for push-on hoses, there are a few options available. One option is to use hose clips or factory swaging to secure the hose in place. Swaging involves crimping a metal collar over the hose instead of using a hose clip. Another option is to use quick-connect fittings, which are designed for convenience and easy installation, allowing for tool-free connection and disconnection of fuel lines. These fittings can range in price from $5 to $20 or more per fitting.
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Teflon/PTFE-lined hoses prevent fuel vapour escape
When plumbing a fuel system, the hose is the vital link that joins all the components together. The type of hose you use will depend on where it is being used. For instance, the hose used for connections inside the tank, which is submerged, can be made of fuel-suitable plastic or rubber and uses push-on fittings. However, push-on hoses, while cost-effective, will allow vapour and fumes to escape, making the cockpit an unpleasant place to be.
Teflon/PTFE-lined hoses, on the other hand, can be used both inside and outside the car. The liner prevents the escape of fuel vapour, so there will be no stale fuel smell inside the car. PTFE also offers the unique advantage of being vapour-free, making it perfect for use inside the cabin. It can transfer any type of fluid while working within a broad range of temperature changes. It is also chemical-resistant and offers weight-saving benefits.
Teflon/PTFE-lined hoses are available in dash 6 (-6) or dash 8 (-8) sizes, which relate to the hose bore and the thread of the fitting. The fittings clamp to the hose with a compression olive, creating a very strong connection. When using these hoses, it is important to note that you must use PTFE hose end fittings with PTFE-lined hoses.
When determining the correct fuel line fittings, it is important to first check the type of fitting required. Most production cars use push-on hoses, with 8mm bore being the most common. The hose can be supplied as plain rubber or with a stainless-steel over-braid for protection against cuts and abrasion. It is also important to measure the diameters and check the thread and bore sizes of the outlets to ensure the correct fittings.
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How to measure fuel line size
To measure the size of a fuel line, you need to determine the inner diameter (ID) and outer diameter (OD) of the tubing. This is because the ID of the pipe is the limiting factor on how much fuel can flow through to the engine. If the ID is too small, the motor may run poorly in high-throttle settings.
The first step is to cut a section of the tubing from a location that has not been stretched over a fitting. You can then use a wrench set to slip the open end over the nipple, trying both a size up and down to find the correct size. Alternatively, you can use vernier callipers or a digital caliper to get the correct measurements.
The ID and OD measurements can then be given to your tubing supplier, or you can check them against the specifications of the replacement material. It is also important to ensure that the material is compatible with the type of fuel you are using.
In-line fuel pump manufacturers often recommend a fuel line diameter that works best with their pumps. When designing a fuel line system for ethanol or methanol, it is recommended to go one or two sizes larger than the gasoline requirement.
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Frequently asked questions
The first point to check is the type of fitting required. Most production cars will have push-on hoses, with 8mm bore being the most common. You can also check the manufacturer's part number to determine the correct fuel line fittings.
The easiest way to tell the size of your fuel line is to use a combination wrench. Slip the open end over the tube and whichever one fits snugly is the correct size.
The inside diameter is more important than the outside diameter. This is because the inside diameter determines how much fuel can flow to the engine, and if the wrong size nib is used for the primer bulb, it will not fit properly or it will leak.
The hose is the vital link that joins all the components of the fuel system together, so it is important to choose the right type. The hose can be fuel-suitable plastic or rubber and secured with hose clips or swaged on. It can be supplied in low pressure (for carburettors) or high pressure (for fuel injection) options.
The fuel line diameter will depend on the fuel type. For example, ethanol will require 30% more fuel than gasoline to generate the same horsepower, so the fuel line diameter should be one size larger than the gasoline requirement.
