Fuel line setup, AN fittings on sending unit 2g AWD?!?

[Beckholt99GSX]

Ok so here is my plans on my 2g AWD, I'm replacing the fuel lines using russell proclassic, -8an feed and -6an return, running a single 300lph pump intank for now (bosch 044 later inline).

Couple issues I have came across was if AN fittings can be fitted to the stock sending unit, or what modifications have to be done to make it work.

The other issue I'm stumped on after realizing that there is also another sending unit on the other side of the gas tank, duh!! Do I need to replace the line that runs between the two sending units also? I guess I do not fully understand the whole return system on my car. I understand that the pump pulls fuel from both sides of the "saddles" through a siphoning system, but I need to get this figured out soon so I can get my car put back together, help me out please, thanks in advance

 

[TSITurbo95]

On the passenger side, there is only a siphoning system, no pump. As for the an fittings, they make a fitting that connects the flared pipe from the pump to an AN fitting, but I can't seem to find it, but someone did it on tuners though, so a search I am sure will bring it up.

 

[Beckholt99GSX]

I tried searching these topics and only came up with partial info and not very many pics, what I really need to know I guess is the actual fitting size and if the hard lines coming out of the sending unit need to be modified (seems kinda silly to increase line size if the start of the line coming out of the sending unit is restrictive. Then I just need to know if the line that runs between the two sending units needs to be enlarged or just kept stock also

 

[agentorange313]

http://www.dsmtuners.com/forums/newbie-forum/418328-fuel-system.html

http://www.dsmtuners.com/forums/bolt-tech/411679-1g-fwd-fuel-upgrades.html#post152694134

read up buddy, I have done a lot of work with fuel system in out cars use AN hose and fittings, so feel free to pm me.

 

[TJCTalon]

Agentorange313 was very helpfull to me when I was purchasing my fuel set up. Great guy.

Tunersnation sells a fitting that works with the factory hardline to 6an. I dont know about 8 an.

Id also like some more info on the return line, and how to set that up.

 

[knochgoon24]

For the feed line, the lines coming out of the sending unit are only 3/8" (-6an) so using -8an line is overkill unless you plan on modifying the hanger later with a -8an bulkhead fitting.

A -6an female connects to the stock feed fine. I have no leaks at all. And others have done it the same way.

For the return, I don't see why you would want to waste the money on replacing it from the firewall back unless, for some reason, you couldn't get the fuel pressure low enough at idle with the stock line.

 

[TJCTalon]

how would you go about just doing the stock plastic/rubber return line in the engine bay?

 

[Beckholt99GSX]

From the info I have gathered so far about the fuel line sizes, I believe most the time I hear people running -6an but only to a certain point (when using E85) before larger line is needed, I had extra line laying around so figured I would just do -8an feed and -6an return that way I wouldnt have to mess with it again, shooting for about 600 on E85 and then next year going closer to 800, just wanted to simplify things

 

[agentorange313]

From the info I have gathered so far about the fuel line sizes, I believe most the time I hear people running -6an but only to a certain point (when using E85) before larger line is needed, I had extra line laying around so figured I would just do -8an feed and -6an return that way I wouldnt have to mess with it again, shooting for about 600 on E85 and then next year going closer to 800, just wanted to simplify things

I currently run -8am hard lines that run under my DSM, with bulk head fittings on both sides, rear and front. I have -6an from the tank to the hard line and the hard line to the rail. I know different sizes is not the best idea, but this allows me the change 2 AN hoses lines to change my set up to 8an.

Just wondering, what size are people using for the return? AN hose is significantly smaller than hardlines of the "same" size.

Id also like some more info on the return line, and how to set that up.

I am using my stock return line. I haven't had a chance to to measure the I.D of the stock line, but I am sure its larger than -4an hose(of course depending on manufacturer). I would not use -4an line for a return, and the next common size up is -6an. So it seems to me its either, hard lines which is larger by nature, or -6an lines for return.

how would you go about just doing the stock plastic/rubber return line in the engine bay?

Are you running an AFPR? Most use a 3/8 line, for the return. I used the stock line, well a replacement hose since I replaced all the lines at once but still rubber, and connected it from my AFPR to the stock return line and clamped it down on both sides.

A -6an female connects to the stock feed fine. I have no leaks at all. And others have done it the same way.

Do you have a picture of this? Do you mean that the the stock flared line mates with an 6 an female fitting? I am confused because the stock line has a inverted flare that is the completely opposite way AN seal. Does an AN hose end mate with the stock line?

 

[DAO 1950]

I don't have the same issues that you are trying to solve, my feed line will only be -6AN. What I think is getting overlooked is the existing feed line. If you take it loose at both ends ( which you will do when upgrading ), why not use it as the return? This will give you a sizable increase in the return line and you won't have to buy the new -6AN lines. I have done this on my old 1G and intend to do it for my 2G. Just remember, there is no pressure in the return. Rubber fuel hose with hose clamps can be used.

 

[knochgoon24]

Do you have a picture of this? Do you mean that the the stock flared line mates with an 6 an female fitting? I am confused because the stock line has a inverted flare that is the completely opposite way AN seal. Does an AN hose end mate with the stock line?

This is one of the few things I didn't take a picture of, but I know it works. I bought STM's tank to rail kit when I did mine. I don't remember what the fitting is exactly, but I know I'm just using a regular -6an fitting and I don't have any leaks.

 

[talonalex92]

I also am guilty of mashing an AN fitting into the fuel hose. No leaks though.

 

[chinola69]

http://www.dsmtuners.com/forums/newbie-forum/418328-fuel-system.html

http://www.dsmtuners.com/forums/bolt-tech/411679-1g-fwd-fuel-upgrades.html#post152694134

read up buddy, I have done a lot of work with fuel system in out cars use AN hose and fittings, so feel free to pm me.

Was going to purchase braided lines to change from fuel tank to filter, after reading the links from above canceled cause of the smell of gas you get.

Now after a suggestion on these lines PTFE / Teflon Stainless Steel Lines was wondering if anyone has tried them and if they emit no gas smell

Thank you

 

[miguelmcv]

I have used Teflon hoses on the Power Steering, But I have no personal experience as Fuel line.
However, I don't think they will emit gas smell, which it is sealed by the Inner Teflon, They are rated at 2600 psi, so a don't think it will emit not even a minimal gas smell.

Here is a regular line and an Inner Teflon Line, so you have an Idea How they are made.

You must be logged in to view this image or video.

You must be logged in to view this image or video.

If you see, the Teflon Line is way, way thinner then the regular line, which is better to route it down the car (It will clear more easy and will hide even more).

Here is some Info from the Teflon Line.
Russell Powerflex Brake & Power Steering Hose - JEGS

I forgot to mention.
Both lines are 6 AN.
One is 6 AN Regular hose, and the other is, 6 AN Teflon hose.

 

[99gst_racer]

http://www.dsmtuners.com/forums/newbie-forum/406755-6an-tank-rail-question.html

http://www.dsmtuners.com/forums/bol...factory-fuel-pump-assembly-rail-question.html

http://www.dsmtuners.com/forums/bolt-tech/370847-fuel-sending-unit-fitting.html


This is the way to do it on a 2G:

You must be logged in to view this image or video.

You must be logged in to view this image or video.

 

[chinola69]

Is there a way that doesn't require welding. Some of us don't have such easy access to a welder. Also anyone running the Teflon fuel lines?

 

[TJCTalon]

Yes I have a AFPR. Uses a barbed fitting with a hose clamp for the return.

I thought I remember reading the factory feed and return lines were very close to 6an. Correct me if im wrong.

 

[miguelmcv]

Yes I have a AFPR. Uses a barbed fitting with a hose clamp for the return.

I thought I remember reading the factory feed and return lines were very close to 6an. Correct me if im wrong.

No, that's not right.
The feed line is almost double size of the return line, and the feed line is not even close to a 6AN (2gs).

 

[Beckholt99GSX]

99gst_racer that looks good, was there any other modification underneath the top of the hanger? And I might have found a full blown hanger for a decent deal at this point I might just snag it, so I dont have to swap anything in my fuel system again besides injectors at some point

thanks for all the imput guys really appreciate it, and the pics were really helpful

 

[99gst_racer]

Is there a way that doesn't require welding. Some of us don't have such easy access to a welder. Also anyone running the Teflon fuel lines?

There's a welder and a weldor in every town these days. You probably have one within 10 minutes of you. You don't have to own the machine to receive the service.

The other way is to retain the kink-prone hard line and buy one of those fittings from the http://www.dsmtuners.com/forums/vendor-announcements/390013-fuel-line-metric-6an-adapter.html#post152920429, and pray they actually eventually ship it to you.

No, that's not right.
The feed line is almost double size of the return line, and the feed line is not even close to a 6AN (2gs).

It is not almost double in size to the return line. And the factory feed line has only a slightly smaller I.D. than that of -6 hose. They're closer in size than you think.

99gst_racer that looks good, was there any other modification underneath the top of the hanger?

No other modifications needed. That's the beauty of it. Simply weld on a bung and it's done. You can run any intank pump without modifying anything.

Here's mine old setup with a Denso Supra TT pump.

You must be logged in to view this image or video.

 

[agentorange313]

This is one of the few things I didn't take a picture of, but I know it works. I bought STM's tank to rail kit when I did mine. I don't remember what the fitting is exactly, but I know I'm just using a regular -6an fitting and I don't have any leaks.

Okay, I included a picture of the 1g fuel hanger feed hard line. It has part of the stock soft line that mated with the 14mm x 1.5 flare fitting.

Can you point out where the STM kit fitting or hose end mates with the hard line? What does this AN fitting exactly look like?

 

[knochgoon24]

On the 2g, it connected right to where the M14x1.5 is in your photo. Male flare fitting to female AN fitting.

The fitting in the STM kit is just a normal -6AN female hose end.

You must be logged in to view this image or video.

 

[99gst_racer]

Okay, I included a picture of the 1g fuel hanger feed hard line. It has part of the stock soft line that mated with the 14mm x 1.5 flare fitting.

Can you point out where the STM kit fitting or hose end mates with the hard line? What does this AN fitting exactly look like?

Lawrence, many people simply thread on a -6 hose end onto the 14mm inverted flare fitting there. It's not something that I would ever recommend (in fact, I recommend against it) because there's no positive seal of a flare or at the thread. Nevertheless, many people have done it and many people don't have leaks. It's a gamble at best.

 

[knochgoon24]

Yeah.... It probably isn't the best of ideas.

 

[agentorange313]

Lawrence, many people simply thread on a -6 hose end onto the 14mm inverted flare fitting there. It's not something that I would ever recommend (in fact, I recommend against it) because there's no positive seal of a flare or at the thread. Nevertheless, many people have done it and many people don't have leaks. It's a gamble at best.

Thanks, I never thought it was a good idea either, never went that route, welded a bung just like your sending unit.

Yeah.... It probably isn't the best of ideas.

Yea thats what I figured, I just wanted to know how people were connecting there fuel lines without a flare fitting. thanks



Just hope all of this info posted allows for people to choose the most effective route for themselves.