How To Upgrade Your Fuel System: EFI Ready Fuel Tank Kit

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Swapping Your Classic Car’s Fuel System to Accept Fuel Injection or Upgrading Your Fuel System is a Worthwhile Project

By Brian Brennan   -Photography By the Author

Maintaining a clean fuel system is imperative to keeping your hot rod running. Whether you are looking to clean up your fuel system or upgrade to keep up with an LS swap, this kit will cover you. In our case, we have a 1965 Chevelle in need of a fresh tank and one that will handle the performance demands going forward. (This tank will also work on ’64-67 A-body cars.)

02 The CPP Complete Fuel Injection Ready Tank Kit (PN MS6467CFIT-K) includes a 255 l_h in-tank pump that supports up to 600 hp
The CPP Complete Fuel Injection Ready Tank Kit (PN MS6467CFIT-K) includes a 255 l/h in-tank pump that supports up to 600 hp. There’s an optional high-flow pump to handle higher horsepower requirements. (For LT motors there is a different tank/fuel delivery system.)

One of the major fuel system components is the gas tank. It’s here we incorporated a Complete Fuel Injection Ready Fuel Tank Kit with a 24-gallon tank (PN MS6467CFIT-K) from Classic Performance Products (CPP) that will be up to the demands of our EFI-equipped motor. The CPP fuel tank kit includes a 255 l/h in-tank pump that supports up to 600 hp. You can also order an optional high-flow fuel pump with the proper installation components ready to handle your higher horsepower needs. Something else to keep in mind as this fuel tank system will work very well with your Chevy small-block or an LS engine. It should also be noted that should you have a carburetor this CPP fuel tank will work just fine. However, to make the system work properly you will need to use a different filter/regulator setup. The main issue here is to regulate the fuel pressure down from approximately 35 psi to something along the lines of 5-7 psi. Additionally, the adjustable-external regulator would be accompanied by a separate inline fuel filter. (Should you be wanting to run one of the LT family of engines there’s a separate system required because of the fuel delivery demands. We will come back and visit this same CPP fuel tank, but this time set up for an LT engine later.) Next stop was onto Hot Rods By Dean to work with Geoff Jones to take care of the installation.

03 The CPP kit includes everything you need internal fuel pump with internal and external filter_regulator, fuel float, and sending unit
Aside from the CPP tank the kit comes complete with all the necessary hardware (PN CPFIIK-255), such as hose and “push to connect” fittings that require no specialty tools. Internal fuel pump with internal and external filter/regulator, fuel float, and sending unit.

There are four major components to a fuel system responsible for delivering fuel to the engine as needed:

  • Fuel Tank,
  • Fuel Pump,
  • Fuel Filter/Regulator
  • Fuel Injectors/Carburetor

Each component must perform flawlessly to achieve expected vehicle performance and reliability. Something to keep in mind. Before installation the fuel tank should be checked for internal cleanliness. It is always a good idea to visually inspect the tank. Since you are starting with a brand-new tank this should be quick and easy. Where we hot rodders get into trouble occurs when we paint or polish the tank before use. Should you do either you need to carefully inspect the inside of the tank for metal debris or anything left over from the painting process.

04 Here you can see the cork gasket that goes between the pump mounting plate and the tank
Here you can see the cork gasket that goes between the pump mounting plate and the tank. Also, note the electrical connection that comes off the top of the pump and attaches to the connection points located on the mouthing plate.
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Why Upgrade Your Fuel Tank?

It’s not as unusual as you may think, this “failure to launch” because of a fouled fuel system. After all the effort, time, and money the last thing you want is to pollute the new EFI with contaminated fuel. Most of us understand that if you take a running hot rod and swap the carb for an EFI the odds are you will need to modify your existing tank, or replace it with an EFI-appropriate tank.

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05 Note the filter sock that is attached to the bottom of the pump. It snaps into position
Note the filter sock that is attached to the bottom of the pump. It snaps into position and the “white” return line should be cut approximately ½ inch above the sock.

Fuel Filters

Aside from the tank, get ready to have two fuel filters. One will be in the tank and one will go after the pump and before the EFI. (There are fuel pumps designed to be external, but we have found the internal pumps have advantages, so we went with the internal pump.) Most modern vehicles with fuel-injection systems use filters rated between 10 and 30 microns.

How Big is a Micron?

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Very fine sand is 62 microns (0.0025 inch). If you have a coffee maker, think of its paper filter, it’s approximately 20 microns. This may vary but you get the idea. Typically, an in-tank filter (before the pump) should be in the range of 25 to 400 microns. This filter is protecting the pump from damage. Next up is the final filter (after the pump), which is 1 to 40 microns. (If you have a high-performance EFI system you may be looking at filters that are capable of 10 microns or finer filters.

06 Here is the “white” return fuel hose that is tie-wrapped to the fuel pump
Here is the “white” return fuel hose that is tie-wrapped to the fuel pump (covered by its protective “coat”).

Fuel Tank Pre-Installation

You will want to test-fit your CPP fuel-injection ready tank; make sure it is properly grounded to the frame and be prepared to install an inline fuel filter/regulator. Once the installation is complete keep in mind not to overfill the tank. You will want to leave room for fuel to expand when it warms up via raised ambient air temperature.

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Should you be using a non-vented cap, as we did, you will need a vent on your tank or filler neck. In our case, the vent is in the tank. The vent should be as high as the highest point on the tank, which includes the filler neck. Make sure there are no dips in the vent line, otherwise you have introduced the possibility of trapping fuel or condensation.

07 There is a cork gasket that goes between the tank and both rings that mount, as in this case, the fuel pump, lines, and electrical hookups
There is a cork gasket that goes between the tank and both rings that mount, as in this case, the fuel pump, lines, and electrical hookups. Make sure to use PTFE Teflon pipe tape; it’s required on all threaded surfaces.

Vent Valve

Part of the CPP kit is a remote-mount rollover vent valve, which performs two vital functions. As part of the gas tank’s vent system, it will allow the gas tank to breathe and not build up pressure or vacuum during operation. The second, and arguably a more important function, is to prevent gasoline from flowing onto the ground from the tank resulting from a rollover incident. A check ball inside the valve will close to prevent gas from running out. Note there are two types of rollover valves: in-tank and remote. The remote-mount rollover style is provided with the CPP fuel system kit. It comes with a screen to assist in keeping out contaminates from your line and tank. It should be noted that not all rollover vent valves come with this feature.

Fuel Tank Installation

As for the actual installation of the tank itself it’s quite simple. The factory tank and your replacement tank should mirror each other’s installation. You will find two tank straps provided in the kit, as they are longer than the stock straps. You can use the gas tank’s original hardware to hold the new longer straps in position. (El Caminos can maintain the use of the original factory straps.)

08 The fuel pump_filter drops through the provided hole in the tank
The fuel pump/filter drops through the provided hole in the tank. Note it houses the output, return lines, as well as the vent line.

Fuel Gauge

As an aside you will want to note the ohm reading of your gas gauge. For instance, should your gauge be stock, such as our ’65 Chevelle, we ordered the CPP VSU-3 sending unit that handles 0-30 ohm. (If you have a ’65 Chevy factory gauge you will need to check. This-year-only gas gauges came with either 0-30 or 0-90 ohm. Clearly a production change at some point during the year.) If you were to have an aftermarket gas gauge such as a set of Classic Instruments standard round universal gauges, then you would order a CPP VSU-240 that handles 240-330 ohm reading. FYI on stock gauges: GM ’64 and earlier the reading would be 0-30 ohm; in 1966 and later the reading would be 0-90 ohm. Ford 1987 and later gauges would be 16-158 ohms; Ford 1986 and earlier would be 73-10 ohms.

Sending Unit

You will always want to test your sending unit before tank/sending unit installation to make sure it correctly corresponds with your gas gauge. Make sure to follow the CPP directions closely when setting up the in-tank fuel pump assembly.

09 Note it houses the output, return lines, as well as the vent line

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The tank itself is mounted via the two lengthened straps. The kit comes with all the necessary hardware and components, such as the fuel pump and both in-tank and external fuel filter/regulator. There is ample hose (intended to be used with today’s gasoline) and push-to-lock line fittings, remote rollover valve, the filler neck, and gas gauge sending unit. When mounting the remote rollover valve make sure that it is mounted to the frame or bracket that places it higher than the top of the tank. The tank should also be mounted vertical to the rollover valve.

Follow along with our Project 1965 Chevelle and see how easy it is to install the CPP Complete Fuel Injection-Ready Tank Kit. This 24-gallon tank will match up well with the demands of our Chevelle going forward. Stay tuned, there is lots more to do on our Chevelle. MR

10 There is a fuel tank vent nipple provided, run the hose to, or better yet above the filler neck opening
There is a fuel tank vent nipple provided. Make sure to run the hose (part of the CPP kit) too, or better yet above the filler neck opening.
11 The fuel sending unit plate has a distinct hole pattern
The fuel sending unit plate has a distinct hole pattern. Make sure to note that and it will save you from starting the installation only to find out that you are a “hole” off.

12 The gasket provided in the CPP kit should line up with the tank 13 Your sending unit plate should match together like this 14 The hardware is included to mount the sending unit on our 65 Chevelle

15 Make sure to install the “Y” fitting as high in the system as possible
The “Y” fitting is supplied to plumb together the vent from the tank and the vent from the fuel pump assembly. Make sure to install the “Y” fitting as high in the system as possible. Ideally, combine both vent lines just before entering the remote rollover vent valve.
16 The CPP remote rollover vent valve is extremely important to both a safe and properly functional fuel delivery system
The CPP remote rollover vent valve is extremely important to both a safe and properly functional fuel delivery system. Make sure to mount it correctly (note instructions).
17 VCPP provides ample push to connect fittings for a very neat and good-looking connection
CPP provides ample push to connect fittings for a very neat and good-looking connection. No special tools are required.
18 The CPP external fuel filter_regulator has a ground strap
The CPP external fuel filter/regulator has a ground strap that goes from the bracket, where the electrical connections enter the filter/regulator, and then attach to the mounting hole portion of the bracket. This provides a secure ground to the frame.

19 Attach the ground to the mounting hole portion of the bracket, this provides a secure ground to the frame 19a Make sure to secure to a good grounding point 21 CPP provides a pair of new lengthened straps 22 These attach to the factory slots in the frame

23 At the front of the tank (nearest rear bumper) a pair of drop-down threaded bolts and nuts are used to hold the forward portion
Although you can use the original hardware, we opted for new hardware for our installation. At the front of the tank (nearest rear bumper) a pair of drop-down threaded bolts and nuts are used to hold the forward portion of the tank within the straps.
24 The shorty metal fuel filler neck and rubber boot are supplied in the CPP kit
The shorty metal fuel filler neck and rubber boot are supplied in the CPP kit.
25 We used a factory-style sealed fuel cap necessitating the use of a remote-mounted rollover vent valve
We used a factory-style sealed fuel cap necessitating the use of a remote-mounted rollover vent valve. The CPP model comes with a filter screen to help prevent unwanted material from entering the tank.

26 The CPP model comes with a filter screen to help prevent unwanted material from entering the tank

27 Remember, check all your connections both to fuel and electrical.
The finished installation features our CPP 24-gallon tank (PN MS6467CFIT-K) in its resting position and ready to go. Remember, check all your connections both to fuel and electrical. Take a short test drive and come back and check again. Safety first!

Sources
Classic Performance Products
(714) 522-2000
classicperform.com

Hot Rods by Dean
(623) 581-1932
hotrodsbydean.com

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