Sylvie Willis
Routing fuel lines can be a tricky business, and it's easy to get it wrong. The key considerations are keeping the lines away from moving parts, such as the drivetrain, and keeping them cool. The lines should be smooth and not have any sharp bends. The fuel line should also be kept away from the scrub line, or the parts of the car that would rub on the ground if a tire went flat. It's also important to consider the length of the lines, as longer lines tend to be more flexible and less prone to breakage.
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What You'll Learn
Keep fuel lines away from rotating parts
Routing fuel lines in a car can be a tricky affair. One of the most important things to keep in mind is to keep the fuel lines away from rotating parts. This includes components like the driveshaft and the clutch. A wayward driveshaft or an exploding clutch can cause a lot of damage if it comes into contact with the fuel line.
To ensure this, one method is to route the fuel lines over the top of the passenger-side inner fender and then down along the curbside of the frame rail and frame connector. This setup helps keep the fuel lines away from the drivetrain, especially the bellhousing. It is also important to mount the fuel lines as high as possible to prevent any potential scrub line interference. The scrub line refers to the parts of the car that would rub or scrub on the ground if a tire goes flat or a wheel falls off.
Another critical consideration when routing fuel lines is heat management. Engines, headers, and exhaust systems generate significant heat, which can bake the fuel in the lines, leading to vapor lock. To mitigate this, it is recommended to route the lines away from direct proximity to these heat sources. An alternative method is to use heat shielding at certain points along the fuel line.
Additionally, it is crucial to consider the accessibility of the fuel filter for servicing. The filter should be mounted in a spot that is easily reachable. When laying out the fuel system, determining the placement of components such as the fuel pump and filters is a good starting point. By following these guidelines, you can effectively route fuel lines while keeping them away from rotating parts and potential sources of damage or interference.
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Avoid kinking or pinching
Bending fuel lines without kinking requires practice and the right techniques. Kinks in the fuel lines can restrict fuel flow, which can lead to performance issues and even engine damage.
To avoid kinking or pinching, it is important to choose the right type of fuel line. Fuel lines are typically made from rubber, nylon, or stainless steel. Rubber is flexible and easy to bend but can become brittle over time. Nylon is durable and resistant to kinking but less flexible than rubber. Stainless steel is strong and corrosion-resistant but requires specialized tools to bend. The type of fuel line chosen will depend on the desired level of flexibility and the specific application.
When installing a fuel line, it is important to inspect it for any kinks or cracks. Secure the fuel line using clamps or brackets, and avoid sharp bends or contact with other components. Route the fuel line away from heat sources to prevent damage or potential fires. Additionally, use a fuel filter to protect the engine from contaminants.
To bend a fuel line without kinking, there are several techniques that can be employed. One method is to use a tubing bender, a tool specifically designed for bending tubing without kinking. Another technique is to heat the fuel line before bending it. This can be done using hot water, a heat gun, or even a hair dryer. When using this method, it is important to heat the fuel line evenly and not to overheat it, as this could cause it to melt or catch fire. It is also crucial to go slowly and carefully to avoid creating kinks during the bending process.
In some cases, it may be necessary to straighten a kinked fuel line. To do this, identify the location of the kink and use a pair of pliers to grip the fuel line on either side. Slowly apply pressure until the kink gives way and the fuel line becomes straight again. This method should be approached with caution to avoid damaging the fuel line.
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Use flexible fuel hoses
When routing fuel lines, it is important to consider the potential issues that can arise. These include keeping the lines away from rotating parts, such as a spinning driveshaft or clutch, and away from the scrub line on a car. Additionally, heat can be a huge concern, as it can cause the fuel to boil and lead to vapor lock.
To address these issues, it is recommended to use flexible fuel hoses. Flexible fuel hoses, also known as AN hoses, are designed to isolate vibration and movement, making them ideal for connecting the engine and the tank. They are typically made of polytetrafluoroethylene (PTFE) or Teflon, which has a high tolerance for heat and can handle very high pressure. PTFE is also compatible with fuel additives and resistant to fuel permeation. However, it is important to note that PTFE hoses can be expensive and require specific fittings.
Another option for flexible fuel hoses is to use those that meet the SAE 30R9 standard. These hoses are designed for use with EFI systems and have a working pressure of 100 PSI or more. They feature a fluoroelastomer inner liner that can handle various fuels, including ethanol-blend fuels, and are emissions-legal due to their resistance to fuel permeation.
When using flexible fuel hoses, it is important to consider the length of the lines. Longer lines tend to apply less strain and are less likely to break in the event of an accident. They also allow for more movement and can eliminate the need for extra couplers. However, it is important to secure them with clamps made for fuel injection, placed every 12 inches or so.
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Avoid heat
When routing fuel lines, it is important to consider the heat produced by engines, especially near the exhaust system and headers. Here are some ways to avoid heat issues when routing fuel lines:
Firstly, it is recommended to keep a safe distance from heat sources. For example, a distance of two inches is generally considered sufficient between the exhaust and fuel lines, while lines should not be closer than six inches to any heat source. It is also advised to avoid sharp bends in the fuel lines, instead opting for smooth and large-diameter bends where possible.
Secondly, insulating fuel lines with heat shields or sleeves is crucial. This helps to cushion the lines from extreme heat, preventing them from becoming brittle and cracking. Heat shields can be wrapped around the fuel rails, providing a barrier between the rails and the radiated heat in the engine compartment. This results in cooler fuel rails, reducing heat transfer to the fuel. Additionally, high-temperature heat tape can be used to secure the insulation and seal any gaps.
Thirdly, some fuel additives can help prevent gelling in cold temperatures, which can cause issues with fuel lines and filters. This is particularly relevant for diesel heaters.
Finally, it is worth noting that the "normal" forward fuel line routing runs alongside the engine, but this can lead to issues with the headers baking the fuel. An alternative routing option is to run the forward line over the top of the inner fender, keeping it away from direct heat sources.
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Route over the top of the inner fender
When routing fuel lines, it is important to keep the lines away from the engine heat, rotating parts, and the scrub line. One way to achieve this is to route the lines over the top of the inner fender. This setup can help prevent issues such as vapor lock, which can occur when fuel boils due to line location.
To route the fuel lines over the top of the inner fender, you can start by building an L-shaped bulkhead fitting mount plate and fastening it to the inner fender. This plate will accept a pair of bulkhead fittings, which will attach to the feed and return lines. The feed line will then connect to the mechanical fuel pump on the engine, while the return line will hook up to a mechanical fuel injection bypass valve or a return-style pressure regulator. This setup keeps the fuel lines away from the engine heat and protects them from potential damage.
It is important to consider the placement of the fuel pump and filter when routing the fuel lines. In some cases, the fuel filter may need to be mounted in a specific location to keep it away from the exhaust system and potential driveline carnage. Additionally, when routing the lines over the top of the inner fender, it is crucial to ensure that the lines do not interfere with the wheel or tire. This can be achieved by routing the lines along the inner side of the rear subframe.
Routing the fuel lines over the top of the inner fender can provide several benefits, including protecting the lines from debris and potential damage. However, it is important to consider the accessibility of the lines for maintenance or repairs. In some cases, it may be necessary to drop the tank or remove the body to access the fuel lines for replacement or service. Overall, this routing option can provide a clean and efficient setup for fuel lines, but it is important to carefully plan the routing to avoid potential issues.
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Frequently asked questions
It is important to keep the fuel line away from rotating parts, such as a spinning driveshaft or clutch, and away from the scrub line on a car. Additionally, heat is a huge concern, and the fuel line should be kept away from the drivetrain.
Modern cars have exposed fuel lines under the car, and it is recommended to maintain at least two inches of air between the exhaust and the fuel lines. The bends in the fuel lines should be made as smooth and as large in diameter as possible.
Short lines tend to be stiffer than longer ones, so using a longer line can help reduce the strain and the tendency to break. It is also important to consider the movement of the engine and use clamps to secure the lines.
Inside the frame rail is considered the safest option, but it is also possible to route the lines outside the frame rail but inside the pinch weld. It is important to maintain a safe distance from the exhaust and to use heat shielding if necessary.
