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Toymods Social Secretary
Location:
Sydney
Registered:
July 2002
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AE71 EFI fuel setup - surge tanks etc.
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Thu, 11 September 2003 02:37
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Ok, i have never really had to do this before, so i am not 100% certain on EXACTLY what should be done.
The fuel setup to be thus far is:
# standard tank
# AUDI/PORCHSE Bosch 921 high pressure pump
# lift pump (not sure on specs)
# surge tank
# standard fuel lines
Now the way i think i'm supposed to set this up is:
# From fuel tank to carby fuel filter
# carby fuel filter to lift pump
# lift pump to surge tank
# surge tank to EFI pump
# EFI pump to fuel rail (along standard feed line)
# Fuel rail to return line
# return line as standard back to the tank.
HOWEVER!!
Some people have mentioned that the lift pump won't flow enough to keep the surge tank full or something like that, so the surge tank needs to have a return back to the tank, or something like this?
I have a 3rd (currently blocked) outlet on the surge tank which i can use as a return, so i just want to know what i should be doing. Thanks 
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Location:
Brisbane
Registered:
May 2002
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Re: AE71 EFI fuel setup - surge tanks etc.
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Thu, 11 September 2003 02:45
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Most people run the return line from the fuel rail back to the surge tank, and the surge tank overflow goes back to the fuel tank.
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Location:
c'town, NSW
Registered:
May 2002
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Toymods Social Secretary
Location:
Sydney
Registered:
July 2002
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Re: AE71 EFI fuel setup - surge tanks etc.
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Thu, 11 September 2003 02:52
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That would mean there would be 4 taps on the surge tank? or three? Mine has three, but i can get another one....
Karl be confused, he is stupid an knows only of carbushitters 
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Location:
c'town, NSW
Registered:
May 2002
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Re: AE71 EFI fuel setup - surge tanks etc.
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Thu, 11 September 2003 02:55
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if u set it up the same as the diagram u will need 4
if u run the return from the fuel rail back to the main fuel tank then u only need 3, but u have to make sure the lift pump can flow enough to always keep the surge tank topped up.
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Location:
Terrigal
Registered:
May 2002
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Re: AE71 EFI fuel setup - surge tanks etc.
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Thu, 11 September 2003 06:04
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I agree with Robs method..
Thats what i've done on mine.. 4 outlets on the surge tank with return line coming back to the surge tank. Never have to worry about it running dry then!
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I supported Toymods
Location:
melbourne
Registered:
June 2002
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Re: AE71 EFI fuel setup - surge tanks etc.
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Thu, 11 September 2003 06:40
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there isnt anything wrong with running the return line back to the main tank, just that your lifter pump has to supply much more fuel than the engine is using, wheras with the return going to the surge tank, the lifter pump only has to supply as much fuel as the engine as using. probly be easier to put another fitting in the surge tank, or just use an internal surge tank and a swimmer pump, but this might be more expensive.
pm me if you want to know the king design for an internal surge tank.
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Club Member
Location:
sydney
Registered:
May 2002
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Re: AE71 EFI fuel setup - surge tanks etc.
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Thu, 11 September 2003 06:45
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My advice is to check the new ADR's on fuel delivery systems as i believe there have been some changes to the regulations recently. Some of these changes may make the surge tank unfeasable, or a hassle with engineering.
for your setup Karl if you want the cheap and reliable method....
obtain a sprinter fuel tank, there seem to be a few that have crashed lately so there should be plenty available, if you cant find one let me know as i may know of one or two laying around.
next buy a AE82 fuel pump and bracket from P&PL there are a couple sitting there as I write this.
weld a small lengthening section to the bracket ( I can help you with that) fit it to the sprinter tank and take the neck off the sprinter tank and replace youre stock tank with the sprinter one.
replace all the rubber lines and clamps with efi type and youre in bussines
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I supported Toymods
Location:
melbourne
Registered:
June 2002
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Re: AE71 EFI fuel setup - surge tanks etc.
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Thu, 11 September 2003 12:54
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IRAllY, do you mean use a carby sprinter fuel tank? do these cope ok without baffling for EFI?
my plan (for 4AGE into AE86) is to use a "whatever is cheap" swimmer pump and an internal surge tank, is it even simpler than this?
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Toymods Social Secretary
Location:
Sydney
Registered:
July 2002
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Re: AE71 EFI fuel setup - surge tanks etc.
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Thu, 11 September 2003 13:15
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Ah, things to think about, i have.
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Club Member
Location:
sydney
Registered:
May 2002
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Re: AE71 EFI fuel setup - surge tanks etc.
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Thu, 11 September 2003 19:48
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yes you can use the standard tank, if you can get hold of the efi tank even better but they are pretty hard to come by and not all that much better in any case as they arent designed for hard cornering.
the trade off with the above mod is that you really need to keep your tank at least 25% full when giving the car a good flogging or you will get surge when making tight right hand turns (fuel runs to the left of the tank away from pickup) I do have a couple of ideas on how to stop this problem but havent trialed them yet. for normal driving you can still get down to almost empty before you start to feel surge if you set the height of the pump up correctly.
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