There are a variety of reasons why someone might consider replacing their old fuel pump with an electric in-tank pump. Here are a few of them. Perhaps you have a historic car with a mechanical pump, but you wish to improve the performance and dependability of the vehicle by installing an EFI system. Alternatively, you could be planning an engine swap with a late model vehicle. In this piece, we’ll be filling up a Torino that has had its engine changed. But, before we get into the specifics of the installation, let’s take a look at how mechanical and electric gasoline pumps work, and consider the advantages and disadvantages of each.
Mechanically operated gasoline pumps, which were ubiquitous in automobiles prior to the 1980s, were typically bolted to the engine block or head. Mechanical pumps do not necessitate the installation of additional circuitry and require minimum plumbing. They are rather quiet, however they are unable to keep up with today’s EFI systems. When using fuel injection, the engine operates at higher fuel pressures than what is delivered by mechanical fuel pumps.
When it comes to retrofit fuel pump alternatives, any Diecast EFI fuel pump module kit is one of the most compact and versatile options available on the market today.
There are two alternative electric fuel system configurations available: one that is outwardly attached and one that is internally mounted. External pumps are typically louder and more prone to overheating than internal pumps. It is less likely that a pump installed in the tank will run dry and burn up because of the surrounding fuel. The facility also maintains a consistent supply of the liquid gold required by the engine. A positive pressure is created in the fuel lines by an internal pump, which aids in the delivery of gasoline to the engine.
Because of its reduced size, we chose an EFI fuel pump module kit from among the several in-tank tank fuel options offered. It can be adjusted to fit into the Torino’s extremely shallow pan without a problem.
The installation was not successful without certain modifications. An opening of 3.5″ was cut into the top of the tank after it had been dropped and cleaned, as well as thoroughly aired out. Torino already had a precise landing location stamped into the tank, so measuring was simple. Cutting the vaporous container, on the other hand, is a perilous proposition. When cutting or welding a tank that previously contained fuel, proceed with caution. It is possible for explosive fumes to linger in the tank for an extended period of time. Consider taking it to a shop that will flush the tank, ensuring that all gasoline vapor is properly gone, and cut it for you if in doubt. Replacement steel and EFI-ready gasoline tanks are available if your tank is crusty, rusted, or otherwise damaged. They eliminate the need for messy repairs.
Measurement for the new placement of the drop-in pump was straightforward due to Torino’s pre-existing stamping of a perfect landing spot into the fuel tank. When upgrading a fuel tank, it is important to remember to use extreme caution when cutting, drilling, or doing anything else that could cause a spark. This is where we used oil to lubricate the cutting area in order to keep sparks from flying around.
We reduced the length of the fuel pump’s line and the size of the mounting bracket to ensure a flawless fit. Remember that the pump assembly can only be shortened so far and that it is designed to be used in tanks with depths ranging from 7 to 12 inches in diameter. Tanks that are shorter than this will necessitate modifications outside of the scope of a standard installation. Following the installation of the gasoline pump in the tank, the wiring and plumbing are completed.
When it comes to electrical hookups, either a low-cost two-pin trailer plug or a more expensive “Weather Pack” connector can be employed. We connected a new power cable through the trunk, down and out to the pump location, simply following the wires for the stock gasoline tank sending unit, which was a straightforward process. The ground wire is connected to a number of other wires that are positioned near the rear bumper mounts. Although the pump housing has 14-inch NPT connections, we used 3/8-inch hard line for the exit and 5/16-inch hard line for the return. Both lines were flared in order to accommodate Ford’s quick-disconnect connectors.
To prevent the gasoline pump from rubbing against the bottom of the trunk, we bonded two pieces of quarter-inch foam gasket material to the top of the pan before putting it back together.
Because the pump housing had 14″ NPT fittings, we had to use adapter fittings to connect our existing 3/8″ hard line and 5/16″ return line to the new pump housing. Both lines were flared in order to accommodate Ford’s quick-disconnect connectors.
Dorman Products’ nylon fuel lines, featuring 3/8″ tube for the outlet and 5/16″ tube for the return, replaced the original metal lines on the vehicle. The lines are routed back along the body and frame, where they are fastened with cushioned hose clamps that are welded to the frame to keep them safe from the heat and movement of the vehicle.
We used Dorman products Ford fast disconnect fittings at the engine to connect to the fuel rail and return lines, as well as to connect to the fitting at the fuel tank’s inlet and outlet. Maintaining the gasoline system in this manner will make future servicing easier.
What comes next? With our fingers crossed, we’ll fill the gas tank with a few gallons of gas to prime the system, pause to check for leaks, and then turn on the engine and check for leaks once more. Success! After stopping at the local gas station for a fill-up, we watched the needle on the Torino’s original gauge increase, showing that everything, including the fuel sending device, was in good working order.