Return Style Fuel System

[Mattman6]

Parts needed
1. Walbro GSS342 - longer than stock fuel pump
2. Aeromotive A1000-6 Part# 13109 regulates from 30-70psi
3. Fuel lines (20 -25ft)
4. fittings
5. fuel filter (1 input, 1 output)

Step 1
Take out the tank. Several bolts need to be unscrewed. Try to have an almost empty tank. It'll weight less.

Step 2
Take out the module inside the tank. Be careful to take out the cap where the fuel pump is located. It has like 4 clips. Use a philips screw driver.

Step 3
Take the stock fuel pump out. Take out the in-tank regulator.

Step 4
Insert Walbro GSS342. Warning, this fuel pump does not fit in the location where to stock pump is located. Put back the cap and tied firmly with 3 straps.

Step 5
Replace one of the fuel lines that goes into the tank with a fuel line. This one goes from the tank to the bottom of the regulator. You gotta be extremely careful here, try not to break the plastic fuel input of the module inside the tank.

Step 6
Installed regulator.

Step 7
Here you got two choices. Either buy a 2002 Ecotec fuel rail, which is already tapped, or tapped the stock fuel rail, that's what I did. Connect a fuel line from the side of the regulator to where the fuel rail is tapped. You'll know where to tapped because the fuel rail the LSJ uses is the same as the cavalier except the LSJ's is blocked. Drill and connect fitting.

Step 8 Verify for leaks and connect vacuum hose. You have to get a T, cut one of the vacuum lines and install. Replace the fuel filter. It needs a 1 input, 1 output type and be aware of the flow directions.

Step 9 Test for leaks. Switch to Run until the pump fills the fuel line. You'll here a small whine and when the fuel pump stops. Remember, you have to do this everytime you start the car. The regulator does not hold fuels in the lines like the intank regulator.

Step 10 Use a wideband to setup the fuel pressure. Set the pressure. Try to set it for 40-41 psi. At vacuum should be 50-51psi.

After the installation, I went to a dyno and set AFR to 10.8. Dyno results after return style and fujita CAI. The KR I got before the return-style, gone.






















Quoted from the SS from jgarciarivera.

Is this old news? I know a lot of people wanted to go that route, just thought I would post this up here

[Mattman6]

Thought I would post up prices and pictures where some of these parts can be found.

Fuel Regulator


http://www.hallspeedshop.com/a10006-...or-p-2223.html

Fuel Pump



http://www.turbowholesale.com/produc...productid=4770

Why would you convert to a Return Fuel System? To raise pressure for a turbo application?

To prevent starvation of the fuel injectors to the farthest of the fuel rail where the fuel lines enter. On a return fuel system, there is a constant fuel pressure inside the rail which means that the fuel injectors are basically getting a equal amount of fuel. On a return-less fuel system, the farthest injectors might not get as much fuel as say the closer ones would.

This can directly affect the performance of that one cylinder (I believe #4). A wideband would show your a/f overall, so if you richen, you'd be richening your total a/f but that doesn't mean that #4 injector would be getting the equal amount of fuel and it could cause that one cylinder to detonate from being lean.

Post taken from NJHK

[Periodic]

very nice find, thanks for posting it up.

[Mattman6]

maybe a sticky is in order

[Periodic]

Originally Posted by Mattman6

maybe a sticky is in order

I'll vote this a sticky, if you vote my autocross 101 a sticky! haha

Eitherway, sticky this. Could be valuable, and for some of the more knowledgeable people here could lead to a very knowledgefull conversation.

[JRelly]

So he got 250hp with just the return system and an intake?

[Mattman6]

Originally Posted by JRelly

So he got 250hp with just the return system and an intake?

thats sure what it looks like, just imagine the possibilities with this

[AlphaJaguar5]

Way to go Matt. See this is the kinda crap we need people doing. Great Job again matt. BTW this is stickified. Periodic I'm going now to sticky yours. We just got our powers today so I can actually do crap now

[JRelly]

Originally Posted by AlphaJaguar5

Way to go Matt. See this is the kinda crap we need people doing. Great Job again matt. BTW this is stickified. Periodic I'm going now to sticky yours. We just got our powers today so I can actually do crap now

Matt did a good job finding info but this isn't his work or setup, so praise should going to jgarciarivera from css.net. But good job finding the info Matt because I hadn't even seen this on css

[AlphaJaguar5]

Originally Posted by JRelly

Matt did a good job finding info but this isn't his work or setup, so praise should going to jgarciarivera from css.net. But good job finding the info Matt because I hadn't even seen this on css

Ok we all know cobalt owners are like canadians, they don't count as people so good job matt for converting your redline to a return style setup

Oh yeah good job to j garcia for yadda yadda yadda something about fuel lol