Ameer Randolph
Installing fuel injection on an old car is a complex process that requires a good understanding of the vehicle's fuel system and access to specialist tools and equipment. The first step is to drain the fuel tank and remove the fuel pump, before installing a new high-pressure fuel pump and fuel injection system. The fuel injectors must then be installed, along with the necessary wiring and connectors. Finally, the fuel tank can be refitted and the engine started, allowing the fuel pump to refill the lines and fuel rails. While this process may seem daunting, there are now self-learning EFI kits available that make it much simpler and more accessible for classic car enthusiasts.
How to Install Fuel Injection on an Old Car
| Characteristics | Values |
|---|---|
| Difficulty | Installing fuel injection on an old car has become a simple process, but it can be tough and dangerous. |
| Cost | Cost is a major reason people choose not to install fuel injection. |
| Planning | An empty tank makes the project easier. Park the car on a flat and level surface, set the parking brake, and raise the car. |
| Fuel hoses | All rubber fuel hoses must be replaced with new ones as older hoses cannot handle the pressure. |
| Fuel tank | Disconnect the fill and vent pipes from the tank. Loosen the bolts on the tank straps and slowly lower the tank. |
| Fuel gauge sending unit | Remove by carefully knocking loose the locking collar and taking the assembly out from the tank. |
| Fuel pump | Mount the new fuel pump somewhere protected under the car, but still accessible. |
| Fuel supply line | Cut a piece no longer than 18 inches and install between the fuel pump and tank with the pre-filter in-line. |
| Relay | Mount near the battery or the main power distribution block and wire according to instructions. |
| Wires | Route the switched output wire with a ground wire to the new fuel pump. Secure the wires to the frame with zip ties. |
| Fuel injectors | Dip the injector tip into engine oil to wet the seals, preventing leaks. Press the injector into the rail until it stops. |
| Fuel rail | Remove bolts and brackets holding the fuel rail in place. Disconnect the fuel line from the fuel rail. Lift the fuel rail off the intake manifold. |
| Fuel injector electrical connections | Plug in the fuel injector electrical connections and reconnect the battery. |
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What You'll Learn
Replacing old fuel hoses
When installing fuel injection on an old car, it is important to replace all rubber fuel hoses with new ones as the older hoses cannot handle the pressure.
Step 1: Prepare the Car
Park the car on a flat and level surface, such as a garage floor, and engage the parking brake. Place a jack under the front crossmember and raise the car so you can comfortably slide under and work. If you have ramps, place them in front and drive the car onto them. Alternatively, you can place the jack under the frame rails and raise the rear wheels off the ground. Remember to always place jack stands under the axle housing, as close to the rear wheels as possible, before carefully lowering the car onto them.
Step 2: Disconnect the Battery
Before working on the fuel hoses, it is important to disconnect and isolate the negative terminal on the car's battery to avoid any chance of an electric spark.
Step 3: Locate the Fuel Filter
Get underneath the car and locate the fuel filter. Place a catch pan or a towel underneath it to catch any leaking gasoline.
Step 4: Remove the Old Fuel Hoses
Using a screwdriver or a wrench, loosen the hose clamps until they slide back and forth. Carefully push and remove the old rubber fuel lines from the mounts on the hard lines. Note that gasoline will immediately exit the fuel lines when they are removed, so be prepared with eye protection and shield your face.
Step 5: Feed the New Fuel Hose
Once the old lines are removed, feed two lengths of the new fuel hose from above (from the engine compartment).
Step 6: Install the New Fuel Hose
Install the new fuel hose onto the fuel pump, fuel line, or carburetor. Tighten the new hose clamps and secure the hose. Ensure that the connections are tight. Do not use old hose clamps as they may cause leaks.
Step 7: Finalize the Installation
Cut any excess hose that you don't need where they meet the fuel pump. Attach any additional hoses or fittings, such as the vapor line and return line, as needed.
It is important to note that fuel hoses come in various materials, including rubber, metal, and plastic, and you should choose the type that is most suitable for your vehicle. Additionally, always refer to your car's repair manual for specific instructions and take the necessary safety precautions when working on fuel systems.
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$512.21
Removing the fuel tank
To remove the fuel tank as part of installing fuel injection in an old car, follow these steps:
Firstly, park your car on a flat, level surface, such as in your garage, and engage the parking brake. Place a jack under the front crossmember and raise the car so that you can comfortably slide under to work. If you have ramps, place them at the front of the car and drive the car up onto them. Now, place the jack under the frame rails and raise the rear wheels off the ground. Place jack stands under the axle housing, as close to the rear wheels as possible, and carefully lower the car onto them.
Next, if your car has a drain plug at the bottom of the fuel tank, locate it and remove it using a wrench. Place a container underneath to catch the fuel and allow it to drain. Once the tank is empty, replace the drain plug. If your car does not have a drain plug, you will need to siphon the fuel. To do this, insert a hose into the tank, creating a seal around the filler neck, and use your mouth or a pump to create suction. The fuel will then flow through the hose and into a container. Alternatively, if you have access to the fuel pump, you can disconnect the fuel line at the engine and use it to fill your container.
Once the fuel tank is empty, you can proceed to remove it. If your car has an access panel under the spare tire or at the front of the tank, you won't need to remove the tank. Place a small board on the jack pad and raise the jack so that it supports the fuel tank. Disconnect the fill and vent pipes from the tank. Loosen the bolts on the tank straps and slowly lower the tank, taking care to also disconnect the fuel sensor wire and fuel line(s). Clean any debris from the fuel tank's sending unit and carefully knock loose the locking collar. Remove the assembly from the tank and clean the strainer with gas or solvent.
Now, you are ready to install the electronic fuel injection system of your choice.
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Installing the new fuel pump
Installing a new fuel pump can be a challenging task, but with the right tools, precautions, and techniques, it can be done safely and efficiently. Here is a step-by-step guide to help you through the process:
First, it is important to perform a thorough diagnosis to ensure that the fuel pump is faulty. This step is crucial as there are many other problems that can mimic a faulty fuel pump. If you are unsure, it is recommended to have a professional mechanic carry out the diagnostics.
Once you have confirmed that the fuel pump needs to be replaced, gather all the necessary tools and equipment, including a new fuel pump, fuel filter, safety gear, and any other components specific to your vehicle. Remember to check if your vehicle has an access plate for the fuel pump, which is usually located in the trunk, under the back seat, or under the spare tire.
Next, park your car on a flat and level surface, such as a garage floor, and set the parking brake. Place a jack under the front crossmember and raise the car to gain access to the fuel pump. If your vehicle has ramps, you can use them to raise the front end. For the rear wheels, place the jack under the frame rails, raise them off the ground, and use jack stands to support the axle housing.
Now, you can begin the process of removing the old fuel pump. Disconnect the filler tube hose, EVAP system connections, wires, and fuel line connections from the pump. Lower the fuel tank and disconnect the fuel lines to completely remove the old pump. Be sure to check the fuel tank for any gunk, rust, or debris, and clean it if necessary, to prevent clogging the new fuel pump.
Before installing the new fuel pump, ensure that you have a new gasket or O-ring, and if needed, a new fuel filter. Carefully install the new pump, making sure to follow the manufacturer's instructions for your specific vehicle. Reattach the fuel lines, wires, and other connections that were previously disconnected.
Finally, reassemble the fuel system and test the new fuel pump to ensure it is functioning properly. Check for any leaks, and ensure that the engine runs smoothly.
By following these steps, you can successfully install a new fuel pump in your old car, improving its performance and reliability. Remember to prioritize safety and always work in a well-ventilated area to prevent the risk of fire or inhalation of harmful fumes.
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Choosing the right EFI kit
When choosing an EFI kit, there are several factors to consider. Firstly, the cost is a major consideration. EFI kits can be expensive, and the price varies depending on the kit's features and capabilities. Some kits may cost around $1000 or more, while others, like the Go EFI 4 kit from FiTech, are available for $995.
Another important factor is the compatibility of the EFI kit with your car's engine. You need to ensure that the injectors in the kit can supply the necessary fuel based on your engine's power potential. Most aftermarket EFI kits are designed for naturally aspirated engines making less than 650 horsepower, but some products cater to higher horsepower combinations as well. Additionally, you should consider the type of fuel system you want to use. There are two primary types of EFI systems: throttle body injection (TBI) and multiport injection. TBI systems are generally more affordable and work by placing the fuel injectors in the throttle body, creating a controlled mixture of fuel and air. On the other hand, multiport injection systems are more precise and ideal for optimal performance but are more expensive.
Furthermore, you should consider the fuel tank and fuel supply when choosing an EFI kit. A new EFI system may not work optimally with an old fuel tank that is full of sediment and rust. You might need to flush and clean the tank, add provisions for a vent and return line, or install an in-tank fuel pump kit. Additionally, EFI systems require a constant and steady fuel supply, and fuel slosh can occur when the fuel level drops below a quarter of a tank, affecting the fuel supply to the pump.
Finally, when choosing an EFI kit, consider the installation process. Today's EFI kits are designed for easier installation, but some kits may require cutting and welding for the necessary sensors. Additionally, you may need to upgrade or replace certain components, such as ignition parts, to ensure compatibility with the EFI system.
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Upgrading the fuel system to high pressure
First, it is important to understand the components of the fuel system, which include the fuel pump, fuel injectors, fuel lines and rails, and the fuel pressure regulator. These components work together to ensure the engine receives the right amount of fuel and runs smoothly.
When upgrading to high pressure, it is crucial to choose the right fuel injectors. Fuel injectors come in various sizes, and it is common to double, triple, or even quadruple the flow rate when upgrading. The injectors should be sized according to the maximum power output of your engine. A larger injector will result in a larger minimum injection, and if this is larger than the required amount of fuel, it will lead to a rich air-fuel ratio and poor engine performance. Therefore, it is important to select injectors that match your engine's requirements without being overly large.
The fuel pump is another critical component. Larger fuel pumps require upgraded wiring to supply them with sufficient power. This upgrade often results in the loss of the factory fuel pump speed control, causing the pump to run at full speed continuously. Consequently, pump wear and fuel heating increase. Additionally, the factory fuel pressure regulator may not be able to handle the increased flow, leading to higher fuel pressure and the injectors spraying more fuel than intended. Upgrading to an aftermarket fuel pressure regulator capable of handling higher fuel volumes and controlling pressure effectively is advisable.
When installing the new fuel pump, ensure it is mounted securely under the car, protected from debris and heat, yet accessible. Follow the manufacturer's instructions for wiring and routing the output wire to the pump. Use solderless connectors for power and ground wires, and secure all wires with zip ties.
Finally, the fuel lines and rails are typically the last components to be upgraded. The stock lines and rails can often withstand pressures beyond stock power levels. However, it is crucial to inspect and replace any old rubber fuel hoses as they may not handle the increased pressure.
It is important to note that upgrading the fuel system requires more than just swapping out old parts for new ones. Modifications may be necessary to ensure the system can handle increased pressures and temperatures associated with higher performance. Improper upgrades can lead to engine damage, so careful planning and execution are essential.
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Frequently asked questions
Installing fuel injection in an old car can improve performance and fuel economy. It can also help you dial in your desired level of performance.
To install fuel injectors, you must first remove the old ones. Disconnect the battery, remove the plastic engine covers, and use pliers to disconnect the electrical connectors on each injector. Then, lift the fuel rail off the intake manifold, bringing the injectors with it. Before installing the new fuel injectors, dip the injector tip into engine oil to prevent leaks. Attach the new injectors and reattach the fuel rail and fuel line. Reconnect the battery and turn the key to the "on" position for 10 seconds before starting the engine.
EFI (Electronic Fuel Injection) kits are now easier to install than ever before. They are self-learning and can be adjusted using a hand-held controller. To install an EFI kit, you will need to remove the carburetor and bolt on the EFI kit. You will also need to install an EFI-quality fuel delivery system, which may require some planning.
You will need to upgrade your fuel system to a high-pressure fuel delivery system, which requires roughly 60 psi. You will also need good lines and connections from the tank to the FI unit, as well as new fuel hoses that can handle the pressure.
The cost of parts for a fuel injection conversion can be up to $600, and labour costs will increase the total cost. EFI kits can cost around $995, and getting a reputable shop to do the installation and programming will also add to the cost.
