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Old 03-27-2007   #1 (permalink)
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Fuel injection conversion...

I'm in the process of converting my carbureted GT40-302 powered Mustang to fuel injection. I've got 97% of the work completed. FMS Cobra lower intake is on and constructed, all wiring is completed, O2s are in place, fuel pump is ready, BAP/TAB/TAD's are all in place, etc. All I have left to do is mount the upper intake, drop the diz in place and complete the fuel lines.

I have several sets of instructions obtained from reputable sources, yet none of them address the fuel return line to the gas tank from the fuel injection system. I don't know anyone in this area with a 5.0 Mustang, so I don't exactly have the option of just calling a friend and asking him to stop by so I can peek at how the car is set up.

Since none of the instructions address the issue, I'll ask first... is a fuel return line necessary? Second, if it is, do I have to drop the fuel tank out of the car and change the fitting on the top of the gas tank for the pickup? There's only one fitting on top of my gas tank, and that was for the single gas line that fed the carb. There's no second fitting for a return into the tank.

Getting the fuel lines sorted out is the last challenge and then the car will be ready to start. I hope to complete that work today after a little research and feedback. Detailed fuel system information would be appreciated. Thanks for any answers you might have.

-Roger
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Old 03-27-2007   #2 (permalink)
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Eveything you need to know man.
http://fordfuelinjection.com/index.p...i+return+lines
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Old 03-27-2007   #3 (permalink)
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Very helpful. Thanks.

That said, does anyone have a picture of the top of a fuel-injected gas tank? I need to see what I'm missing here. Thanks!

-R
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Old 03-27-2007   #4 (permalink)
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On most fuel injected cars, the return, and supply are both in the top of the fuel pump mount. Many performance enthusiasts say the return should be far away from the pump because the fuel returned has been heated by the fuel pump, and the heat exchanged in the engine compartment. I am pretty sure a mustang is the same way as described as above. I've done a couple fuel pumps, and im pretty sure it returns right next to the pump.

Have you thought about trying to find a fuel tank in a junk yard for an 87-93? If its a 5.0 car, you can snag the fuel lines as well, and then you will have the whole fuel system.

Last edited by 1 clean notch; 03-27-2007 at 10:05 AM..
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Old 03-27-2007   #5 (permalink)
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You can get a aftermarket high flow pickup too. Here's a pic though.

Last edited by 91gt347; 03-27-2007 at 10:09 AM..
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Old 03-27-2007   #6 (permalink)
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My sumped tank just has a -6 fitting welded into the top of the tank. It doesn't matter if it's far from the feed. Just make sure it's at the top of the tank so your system has a freeflow return and doesn't add strain on the pumps. Heat would be the only problem as mentioned above....I think. I don't see any cavitation problems coming from the lines being too close.

Good luck.

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