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How to: Add a Fuel Pressure Regulator to a Returnless 04+ Fuel System (Fiero Version)

Explicit_Spade

Explicit_Spade

Perma-Banned! JK LOL
I grabbed a bit of info from a Fiero forum that I'm thinking of using for my own fuel system.

Originally posted by helmet1978:

Grabbed a fuel pressure regulator from the junk yard today, it came from a 3800 N/A but it looks just like the S/C one. Anyone know if this will work?

fuel1.jpg


Cut up the series II fuel rail and started playing with my tube flaring tool:
fuel2.jpg


Heres the fuel setup to work with the Series III returnless rails
fuel3.jpg


This is Darth Fiero's design, used on his LS4 swap. Looks like the simplest way to go in my book. Pressure regulator mounts down by the fuel filter. More pics of this when I get it finished :)

Aeromotive makes factory style clip on connectors. Not cheap ($38 each) but definately nice!
fuel4.jpg


Paul
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Originally posted by helmet1978:

A little more done tonight!

Finished plumbing in the fuel pressure regulator and running the hard vacuum line. Also I flipped the heater hoses in their bracket, should be easier to hook up to the coolant fill neck this way.
fuel5.jpg


Closer shot
fuel6.jpg


This is all on the lower firewall (towards the front of the car) so it won't really be seen once the engine is in place.

Essentially this makes the returnless series III fuel rail into a return system using a section cut from the series II rails with FPR, and tied into the Fiero hard lines near the fuel filter.

More tomorrow!

Paul
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Someone suggested that the fuel stays cooler using this method.

Originally posted by helmet1978:


In the picture, the top of the T goes to the rails, the left goes to the fuel pressure regulator, and the bottom goes to the Fiero fuel filter (feed line from tank).

Enjoy!

Paul
Click to expand...

This all came from helmet1978's build thread at Well, I've gone and done it...Series III 3800SC Swap Begins - Pennock's Fiero Forum

Any thoughts/ tips/ concerns would gladly be appreciated. I intend to do a write-up of my own when I do this to my GP.
 


Its not a mod for gains. 04+ have the FPR in the stock pump. After upgrading fuel pumps, you have nothing to regulate pressure on the fuel system. Tengis suggested switching to a return style fuel system so you can use the FPR in the Series II rails.

This is a method of doing so where you don't need to swap the whole fuel system.
 
This is what I am looking for, a solution to get my fuel system upgraded. I have a 2004, and I want to upgrade my pump without having any other ill effects like worrying about fuel level below 1/4 tank, hard starts, etc.

I was going to convert to a return style, but I am now trying to figure out which vehicle I need to get my donor canister/basket from, and then rob the other fuel line if I can.
I have the regulator floating around here somewhere from the PRJ rails...

Anyways, my goal here is to drop a Walbro in or something similar, since I was told my fuel supply (not injectors) is holding me back on the dyno. I'd like to push the car little further than 420whp.

I'll keep my eyes on this thread.. Thanks for posting it.
 


Explicit_Spade said:
If you're going to PM him to tell him to ignore my posts like you told me that you have been doing to others, you can post it in this thread so others can read it.
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That's not what your infraction said. It specifically mentioned the post where you suggested someone put 5+ washers on longer bolts to bring struts up beyond the hood level to lower a car. And, as I mentioned...his pm's were full. You will have another waiting for you soon.
 
Explicit_Spade said:
Its not a mod for gains. 04+ have the FPR in the stock pump. After upgrading fuel pumps, you have nothing to regulate pressure on the fuel system. Tengis suggested switching to a return style fuel system so you can use the FPR in the Series II rails.

This is a method of doing so where you don't need to swap the whole fuel system.
Click to expand...

You have options... There is no magic involved in fuel pressure regulation in the tank/canister, its just about using the 04 or 05+ regulator setup. The "symptoms" of upgraded fuel pumps are unrelated to anything else here.
 


darkhorizon said:
You have options... There is no magic involved in fuel pressure regulation in the tank/canister, its just about using the 04 or 05+ regulator setup. The "symptoms" of upgraded fuel pumps are unrelated to anything else here.
Click to expand...

alldatadiy said:
107148337

The fuel pressure regulator attaches to the fuel return pipe on the fuel sender assembly. The fuel pressure regulator is a diaphragm-operated relief valve. A software bias compensates the injector on-time because the fuel pressure regulator is not referenced to manifold vacuum. The injector pulse width varies with the signal from the MAP sensor.
Click to expand...

So what you're saying is that as that as long as the stock fpr and canister are used the 04-05 that switch pumps should be fine?

I'm trying to figure this out for sure, because Tengis said http://www.grandprixforums.net/fuel-pumps-everything-255lph-340lph-pumps-51491.html
Tengis said:
I have a 255lph pump that is drop in for 2004 GPs but I really think 04+ people would be better off going to a junkyard and snatching the return line and fuel rail from a 97-03 car so that you can run a FPR.
Click to expand...


I just don't want to run into something like this
afallucco said:
No problem, I will say I was surprised to find the added theft deterrent by the car not starting unless I prime the fuel pump a few times lol.
Click to expand...

afallucco has an 04 GTP according to his signature.
 
The starting issues have nothing to do with the stock regulator... There needs to be a solid check valve and no leaking to maintain pressure in the fuel system so the fuel pump doesnt need to spin the system up to full pressure before it starts... The regulator does not serve this function.
 
I have a decent checkvalve in stock at the shop here... its pretty small and designed to work with corragated plastic tubing. It does have a 65psi pressure release built into it though... might not be the best behind a big boost setup or one that needs tons of fuel.
 


what ever was the outcome on this? Did you convert to a return style system? and if so. what did you change in your tune?

I have heard the hardest part about a returnless system. is the tune.

I am trying to figure out what to do with the fuel system on my 04-08 grand prix.

Does anyone have serious information on the fuel system setup on these? I know they made a change late in 05.. so that would put my 07 in there. im not sure what it was ( from GM ).

thanks
 
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