Katerina Swanson
Installing an inline fuel pump can be a complex process, often requiring custom modifications to the vehicle's tank and careful consideration of safety measures. The process typically involves externalizing the fuel pump and may include adding a high-pressure fuel pump, which can increase noise levels. It is important to note that newer cars often require more pressure than an average inline fuel pump can provide, and finding a safe place to mount the pump can be challenging. In some cases, an inline external fuel pump can be used as an addition to the stock intank pump for performance enhancement. This option may be preferred to replacing the entire pump, which can be a tedious and costly process.
| Characteristics | Values |
|---|---|
| Cost | £35 |
| Installation location | Under the car |
| Installation requirements | Existing fuel gauge/sender unit must be removed |
| Installation method | Cut bracket with a hacksaw, drill hole for 10 mm stud, wrap pump in insulation tape, fit copper bracket, connect fuel pipes |
| Outlet pipe | Warm with a hair dryer and gently bend to fit the new pump |
| Wiring | Connect positive to positive and earth to negative |
| Maintenance | Clean pump filters |
| Mounting | As low as possible in relation to the tank |
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What You'll Learn
Converting an in-tank electric fuel pump to an external inline pump
To convert an in-tank electric fuel pump to an external inline pump, you will need to follow a thorough process:
- Remove the fuel tank by jacking up the car, placing it on stands, and draining the fuel.
- Disconnect the exhaust heat shield, hand brake cables, wiring clips, and pipe clips.
- Remove the filler hose, bolts, and any other necessary components to access the fuel pump.
- Take out the old fuel pump, ensuring you also remove the tank fuel gauge if it is integrated.
- Clean the pump filters if needed, or replace the pump entirely if it is faulty.
- Install the new external inline pump by running wires to the battery terminals, connecting positive to positive and earth to negative.
- Secure a length of tubing to the new pump and insert it into the tank, ensuring it has the same PSI and flow rate as the original equipment to avoid fuel issues.
- Consider using a fuel sump conversion kit, which acts as a fuel surge tank with a high-pressure pump inside, feeding fuel to the engine.
- Mount the external pump as low as possible and close to the tank to facilitate pump priming and prevent vapor lock.
It is important to note that newer cars may require more pressure than the average inline fuel pump can deliver, so ensure you select an appropriate pump for your vehicle's needs. Additionally, always prioritize safety when working with fuel systems, and refer to expert resources or mechanics if you are unsure about any steps in the conversion process.
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The cost of installing an in-line fuel pump
The process of replacing a fuel pump is labour-intensive, which contributes to the overall cost. A mechanic needs to remove the fuel tank from the vehicle, disconnect all fuel lines, and remove and replace the fuel filter. In some cases, interior parts of the vehicle may need to be removed to access the fuel tank, making the repair more complex and costly. Additionally, the cost of the pump itself can vary depending on the vehicle's make and model, with newer, luxury, and large vehicles often being more expensive to repair.
It's worth noting that fuel pump replacement may be covered under warranty, so it's important to check with the manufacturer or dealer before incurring any expenses. Additionally, some vehicles have been recalled due to fuel pump failures caused by defective parts, so it's worth checking the NHTSA's recall website to see if your vehicle is affected.
While it is possible to replace a fuel pump yourself, it is a dangerous job due to the risk of fire. Unless you are very experienced in auto repair and comfortable working with cars, it is strongly recommended to leave this task to a qualified mechanic. A proper diagnosis is key, and a mechanic can verify that the fuel pump is the real problem before replacing it, potentially saving you money.
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The advantages of an in-tank pump vs an inline pump
The decision to install an in-line fuel pump or an in-tank pump depends on several factors, including the desired flow rate, ease of installation and replacement, thermal management, noise levels, and compatibility with the vehicle's fuel injection system. Here are some advantages of an in-tank pump over an inline pump:
Thermal Management
In-tank pumps are submerged in fuel, which acts as a coolant, helping the pump stay cooler compared to an inline pump. This can be advantageous, especially in high-temperature environments or when the pump is working hard to deliver fuel.
Noise Levels
In-tank pumps are generally considered quieter than inline pumps. This is because they are enclosed within the fuel tank, which helps muffle the noise. For vehicle owners who prioritize a quiet ride, an in-tank pump may be preferable.
Fuel Efficiency
In-tank pumps can utilize a bucket setup with a venturi feature that sucks gas from the bottom of the tank. This design keeps the bucket full, even when the gas tank is almost empty, potentially improving fuel efficiency and ensuring consistent fuel delivery to the engine.
Ease of Installation
In-tank pumps are often considered simpler to install than inline pumps, especially when converting a carbureted car to EFI (Electronic Fuel Injection). In-tank pumps, such as the Holley Sniper EFI, come with OEM-style fuel-sending units, ensuring you don't lose your fuel gauge functionality. Additionally, in-tank retrofit energy components are available if you want to reuse your existing fuel tank.
Compatibility
In-tank pumps are commonly used in fuel-injected cars and trucks, and they are less likely to be problematic. Inline pumps may require additional components, such as a regulator, to work correctly with the fuel injection system.
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The hassle of removing a bad fuel pump from the tank
Removing a faulty fuel pump from inside the tank is a challenging task that requires careful planning and execution. Here are some of the hassles you may encounter during the process:
Firstly, it is essential to jack up the car and place it on stands to access the fuel tank. This step can be time-consuming and may require additional equipment or assistance. Once the car is securely raised, the fuel in the tank must be drained into an approved container. It is crucial to handle fuel with extreme caution and ensure proper ventilation to prevent any accidental ignition.
After draining the fuel, the next step is to remove the exhaust heat shield, move the hand brake cables, and detach various components such as bolts, hoses, and pipes. This process can be intricate and tedious, as one needs to be careful not to damage other parts of the vehicle. Once everything is disconnected, the fuel tank can be pulled out to access the faulty fuel pump.
The removal of the fuel pump itself can be challenging, especially if it is stuck or difficult to reach. It may require special tools or techniques to detach the pump from the tank safely. Additionally, there is a risk of spilling or leaking fuel during this process, which needs to be carefully contained and cleaned up immediately.
Finally, reassembling the fuel tank and all the associated components can be just as tedious as the disassembly process. It is crucial to ensure that everything is correctly connected and secured before lowering the fuel tank back into place. Failing to do so could result in leaks or other issues that would require further repairs.
While removing a bad fuel pump from the tank can be a hassle, it is important to note that some vehicles may have access panels that allow for pump replacement without removing the entire tank. Therefore, it is essential to consult vehicle-specific instructions or seek professional assistance to ensure the job is done safely and correctly.
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The noise of an external fuel pump
An in-line fuel pump can be installed externally, often to replace a faulty in-tank pump. In-tank pumps are prone to failure, especially if you are running waste vegetable oil mixes or biofuel. They can also be a hassle to replace, as you may need to jack up the car, drain the fuel, and remove pipes and cables.
If you opt for an external in-line fuel pump, you should be aware that it may produce a noise when in use. The pump is driven by an electric motor, so it will usually make a soft humming sound. This is normal and nothing to worry about. However, other noises like whining, sputtering, or buzzing could indicate an issue with the pump, fuel, or related parts. For example, if the pump is loose, it may make a lot of noise, and tightening it should get rid of the noise.
To reduce noise from an external fuel pump, you can try a few things. Firstly, ensure that your gas tank is not running on empty, as this can cause the pump to overheat and make noise. The fuel helps keep the pump cool, so keeping your tank full may help reduce noise. Additionally, during installation, you can use insulation tape and silicone to reduce vibration and noise. Wrapping insulation tape around the pump and using silicone to secure the pump to the underside of the car can help cut down on noise and provide bonding.
It is important to note that a malfunctioning fuel pump can cause issues with your engine. If the pump is not functioning properly, your engine may stall, surge, or lose power, especially under stressful driving conditions like driving up steep hills or hauling loads. Therefore, if you notice strange noises coming from your fuel pump, it is essential to have it checked and properly installed or replaced to avoid further complications.
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Frequently asked questions
An inline fuel pump can be installed externally, in addition to the stock intank pump.
It is possible to convert an in-tank electric fuel pump to an external inline pump. This involves removing the in-tank pump and connecting fuel pipes to the new pump.
Inline fuel pumps are more accessible and can be modified to keep the existing fuel gauge. They are also a good option if your intank pump is faulty.
Inline fuel pumps may not deliver enough pressure for newer cars. They can also be difficult to mount safely and may produce a lot of noise.
Yes, custom modifications may be required for safety reasons, such as ensuring there is not enough oxygen inside the tank for a fire or explosion.
