DIY: Fuel System Upgrade *Fuel Return Line*
06-06-07, 11:43 AM
#1
DIY: Fuel System Upgrade *Fuel Return Line*
Quick DIY. Not too detailed, but if you're at the point where you can do this then you don't really need that many details. Just a basic guideline of what to do.
Quick Summary:
For those of us running boost, you need to upgrade the fuel system. The stock fuel system is set up as a dead head system where the fuel pressure regulator is inside the gas tank. This prevents us from being able to increase fuel pressure on the onset of boost. Running a return fuel system allows you to increase the fuel pressure and install a high volume fuel system.
Remove intake manifold. Drill and tap the holes for the screws.
Removed ACIS butterfly valve. Good for NA cars, bad for FI. It's a flow restricton and noise maker.
Mount fuel pressure regulator and connect stainless lines.
Picture 2
Run fuel return lines from gas tank to the regulator.
Picture 2
Picture 3
More to come...how to modify the stock fuel pump unit and fuel rail to a return system. Also, how to install a Walbro high flow/pressure pump
Quick Summary:
For those of us running boost, you need to upgrade the fuel system. The stock fuel system is set up as a dead head system where the fuel pressure regulator is inside the gas tank. This prevents us from being able to increase fuel pressure on the onset of boost. Running a return fuel system allows you to increase the fuel pressure and install a high volume fuel system.
Remove intake manifold. Drill and tap the holes for the screws.
Removed ACIS butterfly valve. Good for NA cars, bad for FI. It's a flow restricton and noise maker.
Mount fuel pressure regulator and connect stainless lines.
Picture 2
Run fuel return lines from gas tank to the regulator.
Picture 2
Picture 3
More to come...how to modify the stock fuel pump unit and fuel rail to a return system. Also, how to install a Walbro high flow/pressure pump
Last edited by JeffTsai; 06-10-07 at 05:55 PM.
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06-10-07, 05:59 PM
#8
Updated with more info...more to come tomorrow when I get everything up and running!
bighitbike: They're 440cc RC Engineering Injectors. I scored them for a pretty good deal. They're not HUGE, but they are big compared to the puny 270cc stock injectors
bighitbike: They're 440cc RC Engineering Injectors. I scored them for a pretty good deal. They're not HUGE, but they are big compared to the puny 270cc stock injectors
06-10-07, 07:23 PM
#9
Lexus Fanatic
hey jeff, great job !!! Just a thought, if its possible can you add a parts list. I think it would make this the ultimate DIY.
Looking forward to your updates.
Looking forward to your updates.
Very nice work there you good old DIY 
06-10-07, 10:06 PM
#12
Yep, my car has never been at a shop...well not really. I bought the car brand new around June 2005. It's been to the dealer twice for the two complimentary oil changes and never again since that lol. I do all the maintenance myself with the highest quality filters and synthetic fluids. All the modifications and work on the car is done by me in my garage at home(yes that includes all the suspension work and including the building of my custom turbo setup). I do bring the car to a shop occasionally, but thats only to get something welded since I don't have a welder. Hopefully I can get a TIG welder soon so I can do everything at home 
04-25-09, 10:49 AM
#14
hey jeff what did you do at the gas tank to install the new pump did you take out the stock intank fuel filter i would love to see some pics i am at a stand still thinking i might just weld a new pickup and go with an external pump i am already going to use a inline fuel filter. because i really dont want to mess up the stock plastic pump and filter holder what did you do back there
04-25-09, 11:49 AM
#15
hey jeff what did you do at the gas tank to install the new pump did you take out the stock intank fuel filter i would love to see some pics i am at a stand still thinking i might just weld a new pickup and go with an external pump i am already going to use a inline fuel filter. because i really dont want to mess up the stock plastic pump and filter holder what did you do back there
The assembly the pump and holder are attached to isn't plastic, it's metal. You can just run a Walbro pump(s) or a Denso pump(s) and you will have all the fuel you ever need. They are more or less a bolt up, very little fabrication needed to make them fit. The return line coming into the tank is self explanatory.