FiTech 40015 Instruction Manual
INSTRUCTION MANUAL #40015 - FiTech
FiTech
Fuel Injection
®
Hy-Fuel Tight-Fit In-Tank Retrofit Kit
NOTE: This Hy-Fuel In-Tank Kit can be used with any EFI system, or with the proper low
pressure bypass style external regulator, it can also be used in carbureted installations.
Warning: Caution must be observed when installing any product
involving fuel system parts or gas tank modifications. Work in a
well ventilated area with an approved fire extinguisher readily available. Eye protection and other safety apparel should be worn to
protect against debris and sprayed gasoline. We recommend having this installation performed by an experienced, qualified, and
FiTech approved automotive technician. The finished installation
must be thoroughly checked for any fuel system leaks. The fuel
system is under pressure, so be sure to relieve the pressure before
opening the fuel system. All safety precautions must be observed
when working with fuel.
This quick start manual is designed to get you up and running with
your Hy-Fuel Tight-Fit In-Tank Retrofit Kit. The FiTech Hy-Fuel Tight-Fit
In-Tank Retro-fit Kit is the industry's most innovative fuel delivery
system.
#40015 Kit Contents
1. Pump Main Assembly
2. Return Hose
3. C-Ring (Red)
4. Foam Gasket
5. 255 LPH Fuel Pump
6. (6) M5-0.8 x 25 MM Flat Head
Machine Screws
7. (6) M5-0.8 Keps Nuts
8. Outlet Hose*
9. (2) Tie Wraps
10. (2) Electrical Connections,
Nuts, Washers and Rubber Boots
11. Filter Sock (Version #1)
12. Filter Sock (Version #2)
Figure 1
11.
1.
Caution: Before starting this installation be sure the negative terminal is disconnected from the battery, you have proper eye protection, a fire extinguisher handy, and that you are working with a
clean and free of combustible fumes fuel tank. The installation of
fuel related components should be done in a well ventilated area
free of any possible fire hazards. Gasoline fumes are toxic and
highly flammable. Drilling and grinding can be a potential ignition
source. Smoking is prohibited and extinguish any open flames.
Start with a new fuel tank or have the fuel tank professionally
cleaned for the safest install. Failure to comply with the these warnings could result in injury or death.
Please read the full instruction manual before beginning your
installation. For tech-nical assistance with your Hy-Fuel In-Tank
Retrofit Kit, call 951-340-2624 or go online to www.fitechefi.com
under “tech center”.
2.
5.
6. 4.
*Note - Pump comes with Outlet
hose already assembled to fitting.
Unpack the #40015 Hy-Fuel Kit
Carefully unpack the components of your
#40015 Hy-Fuel Kit. Lay the components out on
a table and compare to Figure #1 above and the
parts list and confirm that you have all the parts.
Take the (#4) Foam Gasket and punch out all of
the holes. The holes are aready die cut but must
be punched out with a small Phillips screwdriver
or dowel rod.
8.
7.12.
RECOMMENDED TOOLS
• Slow speed Drill Motor
• 2-1/8" diameter hole saw
• Round fine file
• Shop vacuum
1
9.
10.
3.
• Screwdriver: Phillips
• Screwdriver: Small Straight Blade
• 3/8" Socket and 1/4" Drive ratchet
• 5/16" Diameter Drill Bit (Optional)
Instruction Contents:
Kit Contents 1
Recommended Tools 1
Special Instructions 2
Features 2
Drilling The Hole 2
Installing Red C-Ring 3
Black & Red Ring Installation 3, 4
Assembling the Pump 4
Installing the Pump Assembly 4
Running a Return 5
Assembly Illustrations 5
Plumbing Schematics 5, 6
Fuel Pressure Regulator 6
Warranty 6
Features
Special Instructions:
• For extended fuel pump life never let car go below 1/8th tank of gas.
• If using hard fuel lines make sure to use high pressure EFI rated lines and flared fittings.
• Make sure that you remove ALL low pressure flex joints on factory fuel lines and replace
them with EFI rated fuel hose and use proper flared connections and clamps. Be careful not
to mix 45° SAE fitting and 37° AN fittings, they look similar but will not work together. 45°
SAE fittings usually come from a hardware store or auto parts store while 37° AN fittings
are the ones supplied by FiTech and most speed shops.
• If using a return line use at least a 3/8" line.
• FiTech does not recommend aluminum fuel lines EVER! Use EFI high pressure fuel hose
on any plumbing in your system where high pressure is present.
• If using Push-Lok style hose and fittings in your fuel system, make sure all parts come
from the same manufacturer Mixing brands of hose ends and hose could cause leaks.
•FiTech's Go EFI systems are designed for unleaded pump gas up to 15% ethanol content.
• Relieve the pressure from within the system before opening the fuel system.
Very important note: Your fuel tank must have a vent or use a vented cap to prevent
pressure building up inside the tank!
The Hy-Fuel In-Tank Retrofit Kit is designed for almost any fuel
tank depending on depth. By mounting the fuel pump in the
appropriate position on the return tube, it can be installed in
tanks ranging from 6 to 12 inches in depth. Note that these instructions and this kit address installtion in stock fuel tanks
(Version #1) as well as Tanks Inc. fuel tanks (Version #2). The
FiTech Hy-Fuel low profile design allows for maximum clear-
Version #1 (Stock Tank)
Caution: Wear eye protection and ensure tank is free of combustible fumes!! Have a radiator shop boil out the tank.
Drilling the hole:
1. The HyFuel assembly must be installed into the fuel tank.
2. Before beginning to cut the 2-1/8" diameter hole, align the red CRing (#3) in a central position on the fuel tank positioned far enough
from edge of tank for clearance for the filter sock (#11). Try to find
a flat area of the tank to make the 2-1/8"" diameter hole. If this is not
possible due to ribs in the tank, the supplied thick foam gasket will
allow installation over ribbed areas.
3. In selecting your hole location, be sure to avoid the stock fuel level
sending unit assembly and stock fuel pump pickup. See Figure 1.
4. With the red ring in position, mark a spot in the center of the ring.
Using a scribe, you can scribe a circle around the outside of the red
ring and then measure from the scribed line to find the center.
5. Now, you are ready to begin your cut, drill a 1⁄4" pilot hole in the
center of the X spot. See Figure #2.
ance from the floorpan of the vehicle. The system comes with
a high quality 255 LPH fuel pump for engines producing up to
600 HP naturally aspirated. It also comes with a 35 square
inch OEM style sock filter (Version #1) to ensure clean fuel,
extended fuel pump life, and a steady pickup to the pump. If
necessary, replacement parts are available from:
www.FiTechEFI.com
X
Drill 1/4"
hole
Fig. #1
6. Then using a slow speed drill with a 2-1/8" hole saw, cut a hole
in the tank. See Figure #3.
Caution edges will be sharp once hole is cut through the fuel
tank.
7. Remove the cut piece and use a file to deburr the sharp edges.
Installing the Red C-Ring
1. Using the Red C-Ring as a template, drill (6) 1/4" holes in the tank.
See Figure #4. Deburr the holes.
2. Thoroughly clean the tank to remove all of the metal chips and
debris inside and outside of the tank. Prior to final installation, it is
important that the inside of the tank is totally clean.
2
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