Ameer Randolph
Fuel lines are an essential component of any vehicle, but their placement and maintenance can be tricky. The positioning of the return line, for example, can affect the performance of the pump and the level of aeration in the fuel. Some sources suggest that returning fuel to the top of the tank is optimal, while others argue for returning it to the bottom. Additionally, the type of fuel line used is important, with some being more resistant to gas and physical penetration than others. Regular fuel lines, for instance, may be resistant to gas internally but less so externally. Furthermore, water in the fuel tank can cause issues, and various methods exist for removing it, such as suspending it with alcohol or pumping out the tank's contents.
Characteristics and Values Table
| Characteristics | Values |
|---|---|
| Return lines | Should follow the pressure line back to the tank |
| Hard lines | Use flexible fuel hose to connect at the engine and the tank |
| Fuel hose | Should be around 6 inches long |
| Fuel hose benefits | Isolates vibration and movement, makes dropping the tank easier |
| Fuel tank water | Can be removed by suspending it with alcohol, then pumping out the contents |
| Fuel tank water | Can be removed by draining the tank, then adding fresh fuel and a new filter |
| Fuel return line placement | Should be at the top of the tank, if possible |
| Fuel return line placement | Returning fuel to the bottom of the tank can cause aeration |
| Fuel return line placement | Returning fuel to the bottom of the tank can make the pump work harder |
| Fuel line hose | Should be resistant to gas internally and externally |
| Fuel line hose | Outer layer should not be soft or spongy |
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What You'll Learn
Return lines should be placed at the top of the tank
When installing a return line in a fuel tank, there are several factors to consider. The placement of the return line can vary depending on the size of the tank, the presence of a tube, and the potential for aeration. While some sources suggest returning fuel above the fuel level, others recommend returning it below the fuel surface to prevent aeration and the formation of bubbles.
One common practice is to install the return line at the top of the tank, especially if it is a larger tank. This method has been used successfully for years without issues, even in the absence of a tube. However, it is essential to ensure that the return line is located as far away from the pickup as possible to minimize aeration. Additionally, a hose inside the tank can be used to direct the fuel below the lowest level, reducing the risk of aeration.
The size of the tank plays a role in the placement of the return line. For smaller cells, it is generally recommended to return fuel below the fuel level to minimize aeration and maintain fuel pressure. Larger tanks, on the other hand, have more volume to accommodate variations in return pressure as the fuel level changes. They also tend to have fewer issues with "bubbles" due to the smoothing out of turbulence.
To further reduce the risk of aeration, it is suggested to use a tube that extends to the bottom of the tank. This setup allows the fuel to be returned below the fuel surface, preventing the pump from working harder due to the head of fuel above it. Additionally, a tube can help disperse the fuel and prevent splashing or foaming, enhancing the overall efficiency of the fuel system.
In conclusion, when installing a return line in a fuel tank, it is generally recommended to place it at the top of the tank, especially for larger tanks. However, it is crucial to consider the potential for aeration and fuel pressure variations, especially in smaller cells. By using a hose or tube to direct the fuel below the fuel surface, you can minimize aeration and optimize the performance of your fuel system.
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Using flexible fuel hose can isolate vibration
When installing fuel lines in a tank, it is important to consider the potential for vibration and movement, especially when dealing with mechanical equipment and piping systems. Vibration can be caused by pumps or other sources and can have detrimental effects on the fuel lines and the overall system. To isolate and mitigate vibration, flexible fuel hoses can be used.
Flexible fuel hoses, such as those made from rubber or other elastomer materials, can effectively absorb and isolate vibration. This is because they have inherent flexibility and damping characteristics that can reduce the transmission of vibrations. By installing a flexible hose between the source of vibration (such as a pump) and the fixed fuel lines, the hose acts as a vibration isolator, preventing the vibration from reaching and potentially damaging the critical pipeline systems. This not only protects the fuel lines but also helps maintain the integrity of the entire fuel system.
The use of flexible fuel hoses offers several advantages in isolating vibration. Firstly, they can accommodate slight misalignments in connections, ensuring a more secure and adaptable installation. Secondly, flexible hoses can reduce stress on pumps and equipment connections, decreasing the likelihood of leaks or failures caused by excessive vibration. Additionally, the flexibility of the hose allows for angular movement and deflection within the piping system, further enhancing the system's overall flexibility and durability.
Furthermore, the length, diameter, and material properties of the flexible fuel hose can be selected to optimize its vibration-isolating capabilities. Experimental research has shown that factors such as hose length, internal pressure, and temperature influence the vibration characteristics. By carefully considering these factors and selecting the appropriate hose, the effectiveness of vibration isolation can be maximized. This ensures that the fuel lines remain intact and functional, even in the presence of mechanical vibration.
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Aeration can be an issue with return lines at the bottom of the tank
Aeration is a common issue with return lines at the bottom of the tank. This is caused by the splashing of fuel, which creates large visible bubbles that can be easily picked up by the pump, especially when the tank is low on fuel. Even in a low-pressure and low-horsepower system with a small 100 GPH pump, almost 100% of the pump's output will return to the tank during idle. This turbulence can draw a lot of air under the surface.
There are a few ways to mitigate this issue. One method is to run the return line to the top of the tank, away from the pump pickup. This configuration ensures that the return fuel stream enters at a low velocity and is a significant distance from the surface of the fuel, reducing the amount of air that is entrained in the return stream. Another approach is to use a header tank, which can help remove aeration. Additionally, cutting slots in the length of the return line tube, with the bottom of the tube 12mm from the tank bottom, can help reduce aeration and evaporation of fuel without causing pressure changes from fuel level or sloshing.
It is important to note that while aeration can be an issue, it may not be a significant problem unless you are using high-performance racing fuel or have a small pump and a cell filled with foam. Some users have reported running their return lines at the top of the tank without any aeration issues. However, others have experienced pump failures due to aeration when returning fuel at the bottom of the tank without a tube.
When deciding on the placement of the return line, it is crucial to consider the specific characteristics of your fuel system, such as the type of fuel, pump size, and cell design. For example, diesel fuel is known to foam more than gasoline, which can impact aeration levels. Ultimately, the goal is to minimize aeration and ensure the efficient and safe operation of your fuel system.
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Water can be removed from fuel tanks by suspending it with alcohol
Water can enter fuel tanks due to condensation and ethanol additives absorbing water from the atmosphere, which has been through heating and cooling cycles. While pumping out and disposing of contaminated fuel is an option, it can be expensive. However, water can be removed from fuel tanks by suspending it with alcohol, specifically isopropyl alcohol, which is readily available. Isobutyl alcohol is also effective, although it may be harder to find due to increased demand for sanitizers.
The amount of isopropyl alcohol needed depends on the size of the fuel tank. For a typical 40-gallon fuel tank, half a pint to one pint of isopropyl alcohol should be enough to disperse the water and allow the engine to run smoothly. Isopropyl alcohol has an octane rating of 105, so adding it to your fuel may affect the way your engine runs by changing the overall octane rating. It's important to note that while isopropyl alcohol can remove water from fuel tanks, it also acts as a cleaner, removing deposits from the fuel system.
Now, let's shift our focus to the broader topic of how to get fuel lines into the tank. The placement of the return line in a fuel tank can vary depending on the setup and personal preference. Some people choose to plumb the return line at the bottom of the tank, while others prefer to have it at the top. If you have a small pump and a cell filled with foam, it won't make a significant difference. However, if you have a large pump without foam, you will likely experience aeration issues, which can be detrimental to your system.
It's worth noting that diesel is known for causing foaming, but even gasoline can cause foaming, which can lead to issues with your pump. To isolate vibration and movement and make future maintenance easier, it's recommended to use a flexible fuel hose to connect the pressure line to the engine and the tank.
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Fuel lines should be fuel-resistant
Fuel lines are vital components of a vehicle's fuel system, transferring fuel from the tank to the engine. They can be rigid or flexible, and their proper functioning is essential for the vehicle's performance and safety. Given the critical role they play, it is imperative that fuel lines be fuel-resistant to withstand the chemical and environmental stresses they are subjected to.
The choice of material for fuel lines is critical to their durability and performance. Steel is a commonly used material for fuel lines, offering strength and resistance to vehicle vibrations. Stainless steel, in particular, is considered the best option for hard lines. Copper-nickel tubing is another option that is bendable and resistant to work hardening and cracking, which can be issues with plain copper.
For flexible fuel lines, synthetic hoses are commonly used. These hoses need to be fuel-resistant to prevent degradation and failure over time. PTFE-lined hoses, for example, are preferred for their compatibility with E85 fuel, fuel vapour resistance, and ability to retard the degradation process. Cloth-covered neoprene is another option, although it is more expensive.
When selecting a fuel line, it is important to consider the type of fuel and the operating conditions. For instance, with the prevalence of ethanol in gasoline, it is crucial to ensure that fuel lines are compatible with ethanol blends to prevent damage and safety hazards. Additionally, temperature extremes can weaken hose materials, so choosing a fuel line that can withstand a wide temperature range is essential.
To summarise, fuel lines play a critical role in a vehicle's fuel system, and their resistance to fuel is a key factor in maintaining the vehicle's performance and safety. By selecting appropriate materials, such as steel, copper-nickel, or fuel-resistant synthetic hoses, and considering the specific fuel and operating conditions, one can ensure the durability and functionality of the fuel lines.
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Frequently asked questions
The first step is to decide where to put the return line in your fuel tank. Some sources suggest that the return line should return to the top of the tank, in free air space if possible. Others suggest that the return line should be placed at the bottom of the tank. If you are running hard lines, it is recommended to use around 6 inches of flexible fuel hose to connect at the engine and the tank.
Dorman Products 800-075 is a cheap, fuel-resistant, and highly rated option. You can also buy fuel lines from AC Delco, the only fuel pump line that is exclusively General Motors GM OE.
You can suspend the water with alcohol, then pump the contents of the tank out after removing the fuel filter and rigging a discharge line in its place.
It is recommended to avoid using a "regular" fuel line hose, as they are only resistant to gas internally. Instead, opt for a product with a protective outer layer, such as Dorman Nylon Fuel Line Tubing.
If your fuel pump is damaged, it may make a stalling noise. You can also check the fuel pressure at the rail to determine if your pump is damaged.
