Regan Brown
Installing a return fuel line for an EFI system can be a complex process, but it's a great way to improve your vehicle's performance. The first step is to choose between a returnless or return-style setup, with the latter being more suitable for high-performance vehicles but requiring more work to install. One popular method is to use a weldless fuel return kit, which is compatible with a wide range of vehicles and does not require specialized tools or welding. The process involves drilling a hole in the top of the tank, installing the return tube, inserting the fitting with a rubber washer, and tightening the bolt. It's important to ensure that the return line is larger than the supply line to allow for unrestricted fuel flow, and some vehicles may require additional modifications, such as rerouting the return line or using a regulator.
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What You'll Learn
Return-style vs returnless fuel systems
When it comes to installing a return fuel line in an electronic fuel injection (EFI) system, you'll need to choose between a return-style and a returnless setup. A return-style system is a simple mechanical cycle where a fuel pump constantly pumps gas from the tank through a regulator to the injectors or carburetor. The fuel pressure regulator then sends any excess fuel back to the tank. This system is generally more suitable for high-performance vehicles as it is more responsive to varying demands.
The simplest way to prepare a vehicle for a return-style fuel system is by purchasing an EFI conversion fuel tank with the return inlet already installed. If a conversion tank is not available for your vehicle, you can install a return fuel inlet on your existing fuel tank. This can be done by using a weldless fuel return kit, which allows you to drill a hole in the top of the tank, install the return tube, insert the fitting with a rubber washer, and tighten the bolt.
In contrast, a returnless fuel system is simpler to set up and is becoming more common in new vehicles due to tightening federal environmental regulations. It uses an in-tank pump and regulator, with a single fuel line exiting the tank and traveling to the engine. The amount of fuel delivered is controlled by a computer that monitors engine sensors, and there is no return line for excess fuel. This reduces harmful evaporative emissions, but returnless systems are more prone to vapor lock and may not be as suitable for high-performance applications.
Retrofitting a returnless system can be expensive and may require a new pump, regulator, and plumbing. Tuning is also important with a returnless system to ensure the amount of fuel sent to the engine is accurate. While a return-style system may require more work to install and can complicate your plumbing system, it offers advantages in terms of performance and responsiveness.
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Using a conversion fuel tank
One option for installing a return fuel inlet is to use a weldless fuel return kit, such as the one offered by Earl's Performance Products. This kit works on any steel or aluminum fuel tank with a flat, horizontal surface on top and is 1/8" thick or less. The installation process is simple: you drill a hole in the top of the tank, install the return tube, insert the fitting with the rubber washer, and tighten the bolt. The unit's low-profile design allows it to be installed in a wide range of different car and fuel tank combinations, and all the components are suitable for pump gas and E85.
Another option for installing a return fuel inlet is to modify your existing fuel tank. This can be done by adding a return line fitting to the fuel tank's filler neck or by removing, cleaning, and welding a return line into a removable metal section of the factory filler neck. It's important to note that you should not be welding or grinding around gasoline or gasoline fumes as it can be dangerous.
If you're converting a factory carb'd car or truck to EFI, you may also have the option to purchase an aftermarket fuel tank that is designed for EFI and comes with an in-tank pump. This can save you the trouble of modifying your existing fuel tank or installing a return fuel inlet.
When preparing an EFI fuel system, you will also need to decide on the fuel supply and return, fuel filters, fittings, and fuel line. It's a good idea to map out everything you will need ahead of time to save time running back and forth to the parts store.
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Using a weldless fuel return kit
Earl's weldless fuel return kit is a quick, easy, and inexpensive way to set up a return-style fuel system. It is suitable for both novices and experts and can be used on any vehicle, regardless of the model or year. The kit eliminates the need for welding or access to the inside of the fuel tank. It is also compatible with steel or aluminium fuel tanks that have a flat, horizontal surface on top and are 1/8" thick or less.
The installation process is simple and does not require any specialised tools. To install the kit, you need to drill a hole in the top of the tank, install the return tube, insert the fitting with the rubber washer, and tighten the bolt. The fitting will then collapse or "mushroom" from the underside, securing the fitting from the inside.
The weldless fuel return kit comes with fixed and flexible in-tank fuel return tubes, a 6AN ORB plug, and installation hardware. It can also accommodate 6AN, 8AN, 5/16", or 3/8" hose barb adapters (sold separately). The 3/8" hose barb feature effectively routes returning fuel below the surface level, eliminating overhead splash.
The kit is made from high-quality 6061 billet aluminium with a knurled and ribbed body that helps prevent rotation. All the components are suitable for pump gas and E85.
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Sizing the return line
Firstly, it's important to understand the basic principles of fuel line sizing. The diameter of the fuel line plays a significant role in the overall performance of the fuel system. A larger diameter generally provides better flow and supports higher horsepower goals. However, it's crucial to strike a balance because overly large lines can cause issues as well. The key is to choose the correct diameter for your specific engine and fuel system setup.
When sizing the return line, it's generally recommended to be one size smaller than the feed line. This is because the return line typically operates at lower pressure and experiences less restriction than the feed line. However, it's important to note that the return line should not be too restrictive, as this can lead to increased fuel pressure and potential performance issues.
The specific size of the return line will depend on various factors, including the engine's horsepower, the type of fuel used, and the unique characteristics of your fuel system. For example, if you're using ethanol or methanol as fuel, you'll need larger lines compared to a gasoline setup. Additionally, the length of the fuel lines comes into play here. Longer lines will require larger diameters to maintain proper flow rates.
In terms of specific measurements, common sizes for the return line include 3/8" and 1/2". However, it's always best to refer to the recommendations of the fuel system manufacturer or seek advice from experts familiar with your specific setup. It's worth noting that some trial and error may be necessary to find the optimal size for your return line, as different sources may provide varying suggestions.
Lastly, when sizing the return line, consider the ease of installation and compatibility with your fuel tank. For instance, Earl's weldless fuel return kit, which is designed for easy installation, can accommodate 6AN, 8AN, 5/16", or 3/8" hose barb adapters, giving you some flexibility in choosing the appropriate size for your return line.
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Cleaning the fuel lines
Using a Fuel System Cleaner:
- Purchase a fuel system cleaner like Redex, which is specifically designed to clean fuel lines and injectors without causing any damage.
- Adding a dose of the cleaner to your fuel tank is a convenient and quick way to maintain the fuel system.
- You can add the cleaner at any time, with any type of fuel, ensuring that you're always staying on top of fuel system maintenance.
- These cleaners help to remove deposits from fuel injectors, improving their performance and reducing emissions.
Using Acetone:
- Another method is to use acetone, which completely evaporates and leaves no trace behind, ensuring no contamination of the fuel supply.
- Remove the rubber portion of the fuel lines.
- Pour acetone into the line and tape a rag loosely to the other end.
- Blow the acetone through the line, and repeat this process until what comes out is clean and clear.
Using Compressed Air:
- Compressed air is a commonly suggested method to clean fuel lines.
- You can use a bicycle pump or an air compressor to blow out the lines from the engine side to the tank side.
- Ensure you have enough pressure to get the air and gasoline flowing smoothly.
Using Seafoam:
- Seafoam is a petroleum-based solvent that removes carbon deposits and gunk from fuel systems.
- Fill your tank with gasoline and pour in a bottle of Seafoam.
- Let your engine idle, and the fuel pump will pull the Seafoam mixed gasoline from the tank, exposing the crud in the lines and breaking it down.
It is important to note that these methods may not work for all types of fuel line blockages, and in some cases, you may need to physically remove and replace the lines. Additionally, always exercise caution when working with any chemicals or compressed air, and ensure you have the appropriate safety equipment.
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Frequently asked questions
A return fuel line returns any excess fuel that isn’t needed in a particular driving situation to the tank.
There are two types of return fuel line setups: return-style and returnless. Return-style systems are less prone to vapor lock issues and are more suitable for high-performance vehicles. Returnless systems are easier to set up but are more prone to vapor lock.
Earl’s weldless fuel return kit makes it easy to add a fuel return line. The installation process involves drilling a hole in the top of the tank, installing the return tube, inserting the fitting with the rubber washer, and tightening the bolt.
The return line should be the same size as the supply line or one size larger. This will ensure that the regulator works properly and there is no restriction in the return.
It is important to ensure that the fittings are slid on the tubing before the flaring process. It is also recommended to clean the lines before attaching them to the car to flush out any debris that could clog the fuel injection system.
