Sylvie Willis
Fuel surge tanks are an effective way to ensure a constant fuel supply to your engine, especially during high-performance driving conditions. They are particularly useful for race cars, which can be prone to fuel starvation during high lateral Gs. By installing a fuel surge tank, you can prevent issues such as fuel slosh, which can cause inconsistent fuel delivery to the engine. The tank acts as a buffer between the fuel tank and the engine, ensuring that the engine always has enough fuel, even during hard cornering or low fuel levels. The installation process involves fitting the tank in the engine compartment and connecting it to the fuel system, with fuel pumps mounted inside or outside the tank.
| Characteristics | Values |
|---|---|
| Purpose | To ensure a constant supply of fuel to the engine, preventing fuel starvation |
| Installation | Installed in-line between the factory fuel tank and the fuel rail |
| Fuel Flow | Fuel is drawn from the factory tank into the low-pressure pump, then flows into the surge tank and towards the engine |
| Fuel Return | Excess fuel is returned to the surge tank, and once the surge tank is full, the excess is returned to the main fuel tank |
| Fittings | Typically three fittings on top (one feed from low-pressure pump, one fuel return, and one return to the main tank) and one fitting on the bottom for feeding the high-pressure pump |
| Capacity | Usually 0.5 to 1 liter, made from steel or aluminum tubing with a diameter of 2.5 to 3 inches and a wall thickness of 0.050 to 0.075 inches |
| Mounting | Surge tanks can be mounted inside or outside the vehicle, depending on the type |
| Pump Setup | Single, double, or triple fuel pump setups are possible, depending on the engine's fuel supply needs |
| Benefits | Prevents fuel starvation, increases fuel flow, protects the engine, and extends the life of fuel pumps |
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What You'll Learn
Understanding the function of a fuel surge tank
A fuel surge tank is an additional fuel storage device installed in a vehicle to improve fuel delivery and prevent fuel starvation. It is particularly useful during high-performance driving conditions, such as racing, drifting, or drag racing, where the main fuel tank can slosh around, causing inconsistent fuel delivery to the engine. The fuel surge tank acts as a buffer or reservoir between the fuel tank and the engine, ensuring that the engine always receives the necessary amount of fuel to run properly.
The fuel surge tank works by redirecting excess fuel from the main fuel tank during periods of high demand and then drawing from the surge tank during periods of low demand. This helps to maintain a consistent supply of fuel to the engine, even when the main fuel tank is low or when the demands of the engine vary according to load. The fuel is stored in the fuel tank, and the fuel pump sends it to the engine. The fuel is then used by the engine, and any excess fuel is sent back to the fuel tank. This flow is regulated by the fuel pressure regulator, which ensures the right amount of fuel is delivered to the injectors.
The fuel surge tank also helps to prevent air pockets from being pumped to the external pump. It sits between the in-tank pump and the external pump, ensuring that the larger fuel pump receives fuel instead of air. The amount of internal fuel pumps used in the surge tank depends on the current and future power goals of the vehicle.
By installing a fuel surge tank, you can ensure that your engine always has the necessary amount of fuel, even during high lateral acceleration moments such as on the racetrack or drag strip. It is a crucial component for high-performance race cars, providing a stable fuel system for maximum power output.
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$69.69
Choosing the right tank
Choosing the right fuel surge tank is critical to effectively utilising your fuel system. Fuel surge tanks work as a buffer, providing constant fuel supply to the engine and minimising the risk of fuel loss. They are particularly useful in high-performance driving conditions, preventing fuel starvation and inconsistent fuel delivery to the engine.
When choosing a fuel surge tank, it is important to consider the compatibility with your fuel pump. Different fuel pumps have different characteristics and power outputs, so it is essential to do your research and consult manufacturer websites or local dealers for advice. Some fuel surge tanks are designed to work with specific fuel pumps, ensuring satisfactory performance and quality. For example, Nuke Performance offers kits designed for single or dual use of specific fuel pumps, such as the Bosch 040 and Deatschwerks DW200.
The capacity and construction materials of the fuel surge tank are also important considerations. Most tanks have a capacity of 0.5 to 1 litre and are made from steel or aluminium tubing. The tubing diameter is typically around 2.5 to 3 inches, with a wall thickness ranging from 0.050 to 0.075 inches. A longer tank design allows trapped air to rise to the top, preventing it from entering the high-pressure pump. Additionally, consider the number of fittings on the tank, as most tanks have three fittings on the top and one fitting on the bottom.
When purchasing a fuel surge tank, it is advisable to buy from reputable companies that offer high-quality products. Companies like MAPerformance provide a wide selection of high-quality aftermarket surge tanks with perks like fast shipping and hassle-free return policies. It is also worth considering companies that offer a wide range of compatible fuel pump brands, such as Nuke Performance, which offers solutions for brands including Deatschwerks, AEM, Bosch, and Walbro.
By carefully considering factors such as fuel pump compatibility, capacity, construction materials, fittings, and the reputation of the manufacturer, you can make an informed decision when choosing the right fuel surge tank for your vehicle.
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Installing the tank in the engine compartment
Installing a fuel surge tank in the engine compartment is a great way to ensure your engine has a consistent supply of fuel and prevent fuel starvation, especially during high-performance driving conditions. Here is a step-by-step guide on how to install a fuel surge tank in the engine compartment:
First, it is important to understand the function of a fuel surge tank. A fuel surge tank is essentially a buffer or reservoir that sits between the main fuel tank and the engine. It stores a small amount of fuel, ensuring that the engine always has enough fuel, even during hard cornering or high lateral acceleration. The fuel is piped to the surge tank by a low-pressure mechanical or electric pump, and then gravity feeds into a high-pressure pump below the surge tank.
When choosing a fuel surge tank, consider the capacity and material. Tanks usually have a capacity of 0.5 to 1 liter and are made from steel or aluminum tubing. The tubing diameter should be around 2.5 to 3 inches with a wall thickness of 0.050 to 0.075 inches. A long tank design helps any trapped air rise to the top, preventing it from entering the high-pressure pump.
Next, decide on the number and type of fittings. Most tanks have three fittings on top: one for the feed from the low-pressure pump, one for fuel returned through the fuel pressure regulator, and one for returning fuel to the main tank. The bottom of the tank usually has one fitting for feeding the high-pressure pump.
Now, it's time to mount the tank in the engine compartment. Choose a secure location that won't interfere with other engine components. You may need to fabricate a custom mount or bracket to secure the tank in place. Ensure the tank is mounted firmly and won't move or vibrate during driving.
Finally, connect the fuel lines and pumps. Follow the manufacturer's instructions for your specific fuel surge tank. Connect the low-pressure pump to the factory fuel tank, and route the fuel line to the inlet on the surge tank. Then, connect the outlet of the surge tank to the high-pressure pump and the engine's fuel rail. Ensure all fittings are secure and tight to prevent leaks.
By following these steps, you can successfully install a fuel surge tank in your engine compartment, improving fuel delivery and protecting your engine from fuel starvation.
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Connecting the fuel lines
Firstly, understand the components involved in the fuel system. The factory fuel tank is the original fuel storage in the vehicle. The fuel surge tank, also known as an FST or swirl pot, is the additional tank being installed. The engine is the recipient of the fuel, where combustion occurs. Ensure you have the correct fittings and lines for your specific vehicle and surge tank setup.
Now, let's begin with the fuel lines. The fuel line from the factory fuel tank should be connected to a low-pressure pump. This pump will pressurize the fuel and feed it into the surge tank. Depending on your setup, the low-pressure pump may be located externally or internally within the factory fuel tank.
Next, we'll connect the outlet of the surge tank. The surge tank will have a high-pressure outlet, typically on top, which needs to be connected to a high-flowing fuel pump. This pump resides within the surge tank and replaces the OEM feed line. From this high-pressure pump, the fuel will be delivered to the fuel injectors, which supply the fuel to the engine.
Additionally, it is important to manage the return of excess fuel. The fuel pressure regulator at the injector rail will regulate the pressure and return any unused or excess fuel to the surge tank. When the surge tank reaches its maximum capacity, this excess fuel will then be returned to the main fuel tank. This ensures a consistent fuel supply and prevents fuel starvation.
Finally, ensure that all connections are secure and properly sealed to avoid any leaks. Depending on your vehicle and surge tank setup, you may need to refer to specific instructions or diagrams provided by the manufacturer.
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Testing the system
Once you've installed a fuel surge tank, you'll want to test the system to ensure it's working correctly. Here's a step-by-step guide on how to do that:
Firstly, check all the connections and fittings to ensure they are secure and tight. This includes the fittings on the top and bottom of the tank, as well as any fuel lines and pumps. It is important to ensure that there are no leaks in the system.
Next, you'll want to fill up the main fuel tank and the surge tank with fuel. Start the engine and let it run for a few minutes to build up pressure in the system. Check for any leaks again at this stage.
Now, take the vehicle for a test drive, preferably in a range of conditions, including high-performance driving scenarios. This could include driving on a racetrack or a drag strip, or any situation where there is high lateral acceleration. During the drive, monitor the fuel pressure and engine performance carefully. Ensure that the engine is receiving a consistent supply of fuel and that there is no fuel starvation, even during hard cornering or when the fuel in the main tank is sloshing around.
If the engine is consistently receiving the necessary amount of fuel and there are no issues with fuel starvation, then your fuel surge tank system is working correctly.
Finally, it is important to regularly check the system for any signs of leaks or damage, and to ensure that the surge tank is always filled with fuel. This will help maintain the performance of the system and protect your engine.
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Frequently asked questions
A fuel surge tank is a miniature fuel tank installed between the factory fuel tank and the fuel rail. It stores a small amount of fuel for the high-pressure pump to pick up if the flow from the main tank is interrupted. This ensures a constant supply of fuel to the engine, preventing fuel starvation.
A fuel surge tank helps to maintain a consistent supply of fuel to the engine, especially during high-performance driving conditions. It also prevents fuel starvation during cornering with low fuel levels in the tank.
The first step to installing a fuel surge tank is to find a suitable tank. The tank is usually mounted in the engine compartment. Fuel is piped to it by either a stock engine-driven mechanical pump or a low-pressure electric pump. A high-pressure pump will be mounted below the surge tank. The fuel then gravity feeds into this pump and goes to the fuel rail.
