The Be All End All: Fuel Return Line Install How To
Ok I've been getting a lot of questions on how to do fuel return line installs so here is a howto off the top of my head on installing these things.....
Mental Note: Have as little fuel as possible in the tank. You will make a mess if it is full or above 1/4 tank and you will hate yourself.
1) Jack the rearend of the car up on both sides and put jackstands under the car to ensure you don't get smushed. Then take off the passenger side wheel with a 19MM socket and wrench.
2) Now looking inside the passenger side rear wheelwell you will see the fuel canister on the fuel tank. Remove the ground strap and the electrical connections to the fuel pump/canister.
3) Now go in the car and start it. It will run for maybe a couple seconds and die. This will bleed out most of the fuel in the system so you don't get sprayed with gasoline!
4) Looking at the passenger side of the tank where the ground strap was connected to that is the regulator you are going to be blocking off. Twist it and it will be able to come right out. Be sure the black O-ring is still on the end of the regulator and if it is not it is still in the hole so get it the F outta there and back onto the regulator. Now time to fill the regulator. Take some JBwaterweld (found at walmart, etc) and looking at the end of the regulator there is a 1/4" little tube coming out the end and around that is like a 3/4" diameter ring that goes deep into the canister. That is what you will be filling. Fill that completely and nicely so that you won't have problems with it. Allow it to dry for the rest of the install.
5) Remove the 2 10MM screws that attack the brake line and fuel evaporator canister in place (just inside the wheelwell bolted inside the wheelwell). Then go underneath the car and on the passenger side strap the holds the tank up remove that nut (13 or 14MM) and allow the evap canister to get out of your way so you can easily cut the filler hose.
6) Now its time to cut the fuel filler hose. It is the about 1 1/4" rubber hose that goes into the top of the fuel tank. Cut it in half at a decent place so you can get to it easily to put the new fuel filler return line adapter in there. Secure the fill adapter with the 2 hose clamps on both sides.
7) Attach the -6an SS hose to the end of the return fuel adapter and run it along the stock fuel line ziptying it SECURELY along the way. Run it up and over the tranny anywhere you see fit.
8) Now if you have a '03 fuel rail, take out the shrader valve in the end of it. If you have an aftermarket rail then don't worry. Attach the -4an or -6an (dependant on fuel rail application) 1' S.S. supply line to the rail.
9) Put the aeromotive regulator together with all the parts and be sure they are tight as hell so you don't have any leaks. Now with the mounting braket mount it to your battery tray in whichever way you see fit and its secure.
10) Attach the fuel supply line to the supply side of the regulator (if you are staring at it the gauge is on the front, the supply will be on the left and the return will be on the bottom piece) Then attach the long ass -6an SS hose that you painstaking ran all the way up the stock fuel lines to the bottom of the regulator.
11) Now that the stock regulator is dry lets put that back into the fuel pump assembly and reconnect the electrical connections to the fuel pump.
12) Replace the fuel evap canister and all the bolts.
13) First prime the fuel pump by turning the car to on (not start). Do this a couple times to reprime the fuel lines. (I always wait for my red light on the gauges to go off then I start my car.)
14) Start the car and check for any leaks. Check the regulator gauge and make it a 58PSI static fuel pressure by turning the top of the regulator screw with an allen wrench either way to lower/raise the fuel pressure. 58PSI is a stock setting.
15) Once you are ready to tune with a mapclamp/SAFC/DTEC etc then tee a vacuum line off the Upper Pressure Pipe or throttle body adn attach that to the regulator nipple. Then start tuning! Good luck!
If anything is missing let me know, as this is all off the top of my head. -Nick@RealTune
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www.realtuned.com 11 Second Club, AEM EMS, Crane 14's, 44lb/Gated/Ported/Bell-Mouthed/Anti-surged S3R
There pics there. Big thanks to mopar for the thread
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8) Now if you have a '03 fuel rail, take out the shrader valve in the end of it. If you have an aftermarket rail then don't worry. Attach the -4an or -6an (dependant on fuel rail application) 1' S.S. supply line to the rail.
will the kit be provided with the -4an fitting for the 03 fuel rail?
Yes we include a 1' section of '4an SS line to go between the rail and the regulator.....BUT if you need a larger diameter for different applications I'm sure we could do that as well. Everything you will need to the install is with the kit. No worries bro
also 4) Looking at the passenger side of the tank where the ground strap was connected to that is the regulator you are going to be blocking off. Twist it and it will be able to come right out. Be sure the black O-ring is still on the end of the regulator and if it is not it is still in the hole so get it the F outta there and back onto the regulator. Now time to fill the regulator. Take some JBwaterweld (found at walmart, etc) and looking at the end of the regulator there is a 1/4" little tube coming out the end and around that is like a 3/4" diameter ring that goes deep into the canister. That is what you will be filling. Fill that completely and nicely so that you won't have problems with it. Allow it to dry for the rest of the install.
No you will be filling in the "ring" around the regulator. The 1/4" tube coming out of it is the fuel supply line. You are just blocking the area around it. You will see it when you get it out. If not take pictures and I can show you what you will need to fill. -Nick
I pm'd aaron about attaching the ends on the hoses... not something I have done before... little help?
The ends of the hose is just basically fitted flare nuts that thread right onto the end of the rail and onto the regulator. Simply thread them on and tighten them
8) Now if you have a '03 fuel rail, take out the shrader valve in the end of it.
sorry to ask prolly a simple question but... do i take off the valve on the rail, it looks welded on... or is it the "tire inflator" looking thing inside the fitting thats on the fuel rail? if so how do i take it out with a simple needlenose pliers and yank it out? holla back thanks in advance...
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The Be All End All: Fuel Return Line Install How To
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