Resolved 1G Fuel Return Line

[DSM_munky_man]

Alright guys, been searching nearly all morning and didnt find anything for a 1G persay, just a few things that didnt answer my question directly. I mostly found 2g and 420a stuff. I have a 1992 Eagle Talon Tsi AWD and it is the early 6 bolt one So I am going to be doing my fuel system this weekend. Dual in tank 255's, -8 line all the way up, AFPR, new rail, filter, then all the fittings.

My question is though, do we have a fuel return line? I think so, but never looked to hard at the rail and stuff, but my buddy (who owns an SRT4, and swears we are mostly the same so he knows everything bout my car too ) says we dont have one cause he doesnt have one. Also, if we do, where does it go in the tank, most common is on the sending unit, but the new hangar i have doesnt have a provision for a return line? So what am I to do?

 

[99gst_racer]

Yeah, all DSMs have a return-style fuel system. I know SRT4's don't from the factory, but it is a common modification in that community. Unfortuntely, I can't remember much about the 1G fuel lines (I'm a 2G guy mostly), so hopefully someone else can chime in on that. Though, you can follow it back from the bottom of the fuel pressure regulator.

 

[DSM_munky_man]

Alright, I am glad to find out that we do have one and it doesnt have to be fabbed up or something, That way I can just run some line form the bottom of the FPR to the hardline. I am just hoping that the line doesnt go to the fuel pump hangar, cause the new one I am pretty sure only has a provision for the -8 line.

 

[kahl23]

Alright, I am glad to find out that we do have one and it doesnt have to be fabbed up or something, That way I can just run some line form the bottom of the FPR to the hardline. I am just hoping that the line doesnt go to the fuel pump hangar, cause the new one I am pretty sure only has a provision for the -8 line.

You don't want to do that, it would negate all the work and money you've put into the system. You need to think of the fuel system like an electrical circuit. Any resistance (restrictions) impede the entire system. Similarly, a small diameter hose that runs for six feet has much more resistance than a small diameter hose that runs for six inches.

Therefore, upgrading to -8 feed and not upgrading the return line will give you less than optimal flow. I recommend taking the stock feed line and converting it into a return line. Good luck!

 

[pbwu1f]

The fuel tank has it's own return line hose. It runs from the engine bay all the way to the side of the tank.

 

[DSM_munky_man]

You don't want to do that, it would negate all the work and money you've put into the system. You need to think of the fuel system like an electrical circuit. Any resistance (restrictions) impede the entire system. Similarly, a small diameter hose that runs for six feet has much more resistance than a small diameter hose that runs for six inches.

Therefore, upgrading to -8 feed and not upgrading the return line will give you less than optimal flow. I recommend taking the stock feed line and converting it into a return line. Good luck!

Alright, from who I bought the stuff from he said the stock fuel line should be sufficient enough, but is there a write up on how to make the stock line a return line? Or is it real simple? I am looking to do this tomorrow and sat. and cant keep delaying it so I would like something to look at .

The fuel tank has it's own return line hose. It runs from the engine bay all the way to the side of the tank.

Sweet, Thanks for that info, just what I was hoping for!!

 

[Gstclipse69]

Well I have to agree as well, I wouldn't use a stock return line with your setup. You could use the stock feed line as a return because I believe the stock feed is bigger than the stock return.
The fuel lines run under the car on the inner side of the frame. If you wanted to use the stock feed as your return then you would need to cut the feed line off where it connects to the stock fuel filter. Then run a hose from your fuel pressure regulator to the 'now return line'. Then follow the metal hose to the back of the car and by some means plumb that line back into the fuel tank. Yes the stock fuel hanger has a provision for the return. I am not sure why your new one does not. Can you post a pic? Where did you get it?

 

[DSM_munky_man]

Well I was working on the car today and it looks to me like they are both the same size. If they arent then the return is only slightly smaller then feed. Cause I looked at both lines in the engine bay and they are about the same I would say if they aren't then it is damn close. And on the nipple that is supposed to go on the bottom of the regulator it will go in the stock rubber return line. I may be able to get pics up tomorrow of some stuff.

So all my stuff is hooked up and in and plumbed and looks sweet as shit!! I will have some pics up, but I forgot my cam in the garage. Now just waitin on injectors!! Hopefully they are here in the front office. I hate Fedex here they never leave a note on the freaking door to say they came they just leave it at the front office and I never know if they came or not!! I dont even think they come to the door to knock cause according to the tracking number it was here thursday, the day I waited for freaking ever for them!! oh well, Iwill check today at the offie and see whats up!!

oh and for sure the return line is the same size as the feed line stock.

 

[92tsiawdguy]

You don't really need to upgrade the return line. Its about the same size as 6an line. I run 10an feed and 6an return. The more fuel you use the less you have to return to the tank. But then again I have a fuel pump speed controler so I don't over run my return line. But iven been told by many 700hp guys that the stock return is plenty big enough.

 

[92tsiawdguy]

Oh and the stock return is smaller then the stock feed line. Most people will use the stock feed line as a return line because its bigger. Its easy to do.

 

[DSM_munky_man]

I don't think that they are a different size. I looked at both of them and in the engine bay and followed them underneath and they run next to eachother and they are the same size, unless the inside is a different diameter.

And SCORE!! My injectors and link are here!! WOOP WOOP, will be doing install later!

 

[donniekak]

I don't think that they are a different size. I looked at both of them and in the engine bay and followed them underneath and they run next to eachother and they are the same size, unless the inside is a different diameter.

And SCORE!! My injectors and link are here!! WOOP WOOP, will be doing install later!

Do you have a socketed eprom ecu?

 

[DSM_munky_man]

Of course I do! Why wouldn't I silly! I am not as noobish as I seem!

 

[92tsiawdguy]

Measure them they are differnet.

 

[DSM_munky_man]

I'll check again tonight when I go back out but when I was under there they both looked the same running to the tank

 

[92tsiawdguy]

I would'nt lie to you. The ID is different.

 

[Stapl3]

From the dead. Does anyone know what size the return fuel hose is? (I assume the red circle is the return)

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

 

[stealthee]

My Talon didn't have a stock tank when I got it, but I believe the return is like 1/4" or 3/16" It's not very big. I'll be running dual -10 to a single -8 for feed and a -6 for the return, on the Talon. On my 3000GT I'm going to run -6 feed, and then make my OEM feed my return.

 

[CrackedDSM]

It's 5/16. I had some 3/8ths hose though and it fit over just fine and tightened/sealed great.

Literally just redid my fuel system.

 

[Stapl3]

My line is leaking by the rear axle, there is a metal section that rusted out. I do have -6 line to do it, but now that I poke around in the car I'm thinking of just replacing the line from under the firewall, or maybe from the fpr, to the tank with high pressure fuel hose and proper clamps. Using pushlock and all the fittings to just go on a single barb on the tank seems silly. This car isn't exactly a prize either, so while I'm not one to do hack work, it doesn't feel exactly wrong to use a long section of rubber line.

 

[CrackedDSM]

Honestly that’s what the PO did to my car. He used Goodyear fuel hose from fpr to tank and it worked fine. It was just 10+ years old and I wanted to do PTFE stuff.