2G Replacing complete fuel return line

alice · Mar 3, 2010

In the next few weeks I am going to be essentially replacing every line on my car. I'm deleting the ABS with all new brake lines, new fuel supply line, and now I want to do something about the fuel whole fuel return line. Has anyone replaced the entire fuel return line on a 2g AWD? I don't remember what the fitting on the sending unit looks like but I figure it's similar to a push lock fitting. I am thinking I can get a good length of rubber fuel line, slip it to the push lock fitting on my AFPR and then slip it over the return fitting on the sending unit. Your thoughts please.

GRAVEDIGGER · Mar 3, 2010

That should work just fine :thumb:

Boosted98gsx · Mar 3, 2010

I would recommend running SS braided line under the chassis. Just not someplace I'd want pushlok hose where a rock, shard of glass, badger, squirrel, rabid sea bass, etc can get to it and slice it open.

alice · Mar 3, 2010

Boosted98gsx said:
I would recommend running SS braided line under the chassis. Just not someplace I'd want pushlok hose where a rock, shard of glass, badger, squirrel, rabid sea bass, etc can get to it and slice it open.

Very good point I did not think of. If I did go with ss line or the russel black line how would I go about attaching it to the sending unit? Could I run the SS line to the sending unit and the AFPR and just use standard hose clamps to attach it?

mike96 · Mar 3, 2010

alice said:
Very good point I did not think of. If I did go with ss line or the russel black line how would I go about attaching it to the sending unit? Could I run the SS line to the sending unit and the AFPR and just use standard hose clamps to attach it?

the fuel return line just has a short piece of rubber hose that runs between the hard line and the sending unit, so as long as you dont mind the SS braiding flopping around in the breeze then that would probably work fine.

Boosted98gsx · Mar 3, 2010

alice said:
Very good point I did not think of. If I did go with ss line or the russel black line how would I go about attaching it to the sending unit? Could I run the SS line to the sending unit and the AFPR and just use standard hose clamps to attach it?

Depends on the size of the AN line you want to run. -6an is 3/8" diameter, so it SHOULD just fit right over the OEM sending unit return barb.

The OEM line is equal to and arguably larger than -6an, so if you are doing this for performance benefits, you would be wasting money to replace it with -6an.

If you go with -8an or larger, you will need to add an AN bulkhead to the sending unit to get the full benefits of it.

alice · Mar 21, 2010

I would like to replace the fuel return line with hard line again because I don't want anything tearing into it.

alice · Apr 4, 2010

Does anybody know for sure if the OEM hard fuel return line is larger than -6an? I don't want to go smaller and I am not doing this for performance benefits. I figure I might go with -6an from the AFPR to the sending unit as long as I won't lose any performance. I would only be worried that, if the -6an is smaller, the fuel pressure might rise uncontrollably.

talonalex92 · Oct 12, 2011

I know this is old, but I want to clarify to those that are reading this thinking the information is right. The OEM fuel RETURN line is not -6. It is 1/4 inch hardline under the car, and rubber clamped hose on the ends to goto the motor and pump. Not anything else. The OEM pressure line is 3/8. This is what everyone is comparing the -6 to. Just want to prevent misinformation from spreading. :thumb:

knochgoon24 · Oct 12, 2011

I can't stress enough how important it is to run a line with some sort of tough exterior. Rubber line WILL NOT survive. I have the Russel Proclassic line run from tank to rail for my feed, and it has taken quite a few shots from rocks and it's holding up fine. However, the clamps I used to attach it along the pseudo-frame rail are starting to look pretty rough.

Jkorny169 · Jan 4, 2013

talonalex92 said:
I know this is old, but I want to clarify to those that are reading this thinking the information is right. The OEM fuel RETURN line is not -6. It is 1/4 inch hardline under the car, and rubber clamped hose on the ends to goto the motor and pump. Not anything else. The OEM pressure line is 3/8. This is what everyone is comparing the -6 to. Just want to prevent misinformation from spreading.

The oem pressure line is 5/16 not 3/8... for 2g's at least.

Boosted98gsx · Jan 8, 2013

Boosted98gsx said:
I would recommend running SS braided line under the chassis. Just not someplace I'd want pushlok hose where a rock, shard of glass, badger, squirrel, rabid sea bass, etc can get to it and slice it open.

Not to stroke my own ego (ok, it is) but more people need to + rep this post. Afterall, how many people can correlate Dr Evil and DSM's with such hilarity?

Jkorny169 said:
The oem pressure line is 5/16 not 3/8... for 2g's at least.

If I remember correctly (moreso to the topic at hand), the 2g OEM hard return line is 10mm (.394"), larger in dia than -6an (.375").

Total Eclipse · Jan 9, 2013

I personaly have ss lines from tank, all the way up, and back to the tank. I just cut the inlet tubes on my hanger, and tig welded on -6 fittings. For the pick up, I used the stock pickup (cone/tube part) and trimmed the -6 gulkhead fitting to the proper length, and tig welded them together. That way the fuel pump changes just like stock. works great!

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