CA18DET Installation 6 - Fuel System (Second attempt)                Last Updated: 27/07/2008 So the fuel pumps in the metal box idea didn't fly in the end - needed a rear firewall to make it safe and there were some other potential issues I could see; like lifting the fuel that much higher than the fuel tank, the noise and whatever other problems it might entail so scratch fuel concept 1: After experimenting with a few possible locations of fuel pumps under the car.....I made some decisions EFI pump is mounted is the high bit of floor after the diff...had to get a little creative holding up the fuel pump whilst I worked the bolts in (tricky when there's no one around the hold things for you) EFI pump mounted Marked some holes for the lift pump Lift pump mounted (surge tank sitting in place but not mounted) Now the fuel line from EFI pump to fuel rail needs to be bent up - I made a coathanger wire prototype to copy with the 5/16" bundy tube Then I started bending - Bend 1 looks good I did some practice before bend 2 to work out where to mark it so my marker is the start of the next bend, same for bend 3 Not too bad... Here's where is comes up the engine bay...still a little long. Finished product - fuel rail Now connect up some pipes. 1: Fuel return line to fuel rail - the fuel return pipe is 6mm, the fuel rail pipe is 8mm, so I picked up some of these step down pipes....pretty neat. 2: Fuel supply line to fuel rail (with EFI fuel filter in between) 3: EFI pump to fuel supply line Now comes the hard ones - return line is on the top of the fuel tank (which you can't see without dropping the fuel tank) So have to disconnect some piping Now drop the fuel tank - 5 bolts Can see the breather pipe now... Disconnect breather pipe and plug for fuel guage Don't know what this second pipe is for - it T pieces into the filler neck right at the fuel cap...but doesn't seem to have anywhere to go down this end... Anyway - to return fuel through this breather pipe I'll need to T piece into it...so I went and bought the fittings for a 10mm, 10mm, 8mm T pieces (well really a 3/8, 3/8, 5/16") but here it is. Not to connect the surge tank overflow into this T piece Now connect outlet of lift pump into surge tank Now the return line from the fuel rail ends up here....the pipe seems a little long so I'll cut it up to size and connect to the surge tank Also this is the other end of the 6mm to 8mm - so another adapter is needed Whilst the fuel tank was dropped I also put a fuel pipe on the inlet of the lift pump - this will get fuel from the original pick up point in the fuel tank Now I have to connect the other end of that T piece back into the fuel tank....this is the hardest bit of all as I have to hold the tank, push it onto this pipe and push the pipe into the fitting. I lost a bit of skin and muscle in this operation Now tighten up the filler hose and re-mount the fuel tank Now the original fuel pick up pipe will be replaced with the one connected to the inlet of the lift pump Fit fuel filter between fuel tank pick up and surge tank. Fit filter between surge tank outlet and EFI pump inlet Connect up EFI pump to filter Now I got some clamps to secure the hose to the floor of the car - just drill into the floor with self tapping screws Now clamp up the outlet of EFI to the fuel rail Clamp fuel rail to floor Now just tighten up all the hose clamps on the fuel rail side, including the EFI filter.