The FiTech Dual Quad EFI system is a powerful solution for high-performance vehicles, designed to optimize fuel delivery and engine performance. For users looking to upgrade their fuel systems, the installation process requires careful planning, attention to detail, and a thorough understanding of both mechanical and electrical components. This guide is based on detailed instructions from official installation materials and user reports, providing step-by-step procedures, safety guidelines, and troubleshooting tips. Whether you are a seasoned DIY mechanic or a professional installer, this article aims to ensure a successful and safe installation of the FiTech Dual Quad system.
Safety First
Before beginning any work on the fuel system, it is imperative to follow strict safety protocols. Fuel is both toxic and highly flammable, and any oversight can lead to serious consequences, including fire or explosion. The installation process involves high-pressure fuel lines, electrical connections, and the potential for residual fuel in existing systems, making safety a top priority.
- Disconnect the Battery: The first step in any installation involving the fuel system is to disconnect the negative terminal of the vehicle's battery. This prevents accidental activation of the fuel pump and minimizes the risk of electrical sparks.
- Relieve Fuel Pressure: If the installation involves replacing an existing fuel system, it is essential to relieve residual pressure from the fuel lines. This can typically be done by removing the fuel pump relay and cranking the engine until it stalls.
- Ventilated Work Area: All work should be performed in a well-ventilated space. No open flames, smoking, or sparks are allowed in the vicinity of fuel-related tasks.
- Fire Extinguisher: A Class B fire extinguisher, suitable for flammable liquids, must be readily available.
- Protective Gear: Wearing safety glasses and nitrile gloves is strongly recommended to protect against fuel exposure and potential eye injuries.
Fuel Tank Preparation
The installation of the FiTech Dual Quad system typically begins with the removal and preparation of the fuel tank. This step is critical, as improper handling can lead to contamination, leaks, or damage to the tank.
- Draining the Tank: The fuel tank should be completely drained before beginning any work. This can be done using a siphon or by running the tank as low as possible. Any residual fuel should be collected and stored responsibly.
- Tank Access: The method for accessing the fuel tank varies depending on the vehicle. In many cases, it involves removing the rear seat cushions to access the tank from underneath the vehicle or lowering the tank for easier access. The tank must be supported securely to prevent tipping or damage.
- Disconnecting Lines and Wiring: Before removing the tank, all fuel lines, vent lines, EVAP lines (if applicable), and electrical connections must be carefully disconnected. It is important to note the routing and connections of these lines for proper reinstallation later.
Once the tank is removed and cleaned, any existing fuel pump assembly should be carefully inspected. If the tank is old or suspected of internal corrosion, it is highly recommended to have it professionally cleaned and sealed. Rust and debris can severely damage the new pump and filters.
Installation of the FiTech Pump Assembly
The new FiTech pump assembly includes several components that must be assembled correctly before installation. This includes the fuel pump, sock filter, fuel level sender (if included), wiring connections, and outlet fittings.
- Assembly of Components: The pump should be attached to the hanger or bracket according to the kit's instructions. All connections, including O-rings and gaskets, should be inspected to ensure they are present and correctly seated. The pump's orientation within the tank must be verified to match the manufacturer's specifications.
- Sealant Application: In some cases, a specific sealant may be required for the tank flange. It is important to use only the sealant recommended by the manufacturer, as petroleum-based sealants can degrade over time and cause leaks.
- Installation into the Tank: The assembled pump should be carefully lowered into the tank, ensuring proper alignment. The lock ring or fasteners should be secured according to the manufacturer's torque specifications. A proper seal must be ensured to prevent fuel leaks.
After the pump is installed, the tank is ready to be reinstalled in the vehicle. All fuel lines, vent lines, and EVAP lines should be reconnected, ensuring they are securely fastened and free of kinks. The tank straps must be tightened to the correct torque specifications, avoiding over-tightening which can cause damage.
Fuel Line Routing and Connections
Routing the fuel lines correctly is essential for both performance and safety. The high-pressure fuel feed line and return line must be routed along the vehicle's frame rail, avoiding heat sources, sharp edges, and moving parts. Proper securing of the lines with clips or clamps is necessary to prevent vibration-related wear or damage.
- Fuel Line Connections: The fuel lines should be connected using the provided FiTech fittings and high-pressure EFI-rated hose. AN or push-lock fittings must be tightened according to manufacturer specifications using appropriate tools. Open-end wrenches should be avoided to prevent slipping and potential damage to the fittings.
- Leak Checks: After installation, all connections should be double-checked for tightness. A fuel pressure test is a mandatory step before the first engine start to ensure there are no leaks in the system.
Electrical Connections and Relay Setup
The electrical components of the FiTech system include a wiring harness, relay, and fuse. These components are critical for the safe and reliable operation of the fuel pump and must be installed with care.
- Wiring Harness: The wiring harness included in the kit is specifically designed for the pump and controller. It features appropriately gauged wire to handle the pump's current draw and includes sealed connectors that resist corrosion and vibration. Undersized wiring should never be used, as it can pose a fire hazard.
- Relay and Fuse Installation: If the kit includes a relay, it must be mounted securely and connected to the vehicle's power supply. The fuse should be installed as close to the battery as possible to minimize voltage drop and ensure protection against electrical faults.
The wiring must be connected in such a way that the fuel pump only activates when the ignition is in the RUN position, not in the ACC position. This ensures that the pump does not run continuously, reducing the risk of overheating or electrical failure.
Final System Checks and First Start
Before starting the engine for the first time, several final checks must be completed to ensure the system is properly assembled and safe to operate.
- Double-Checking Connections: All fuel line fittings, hose connections, and electrical connections should be verified for tightness and correct polarity. Ground connections must be secure to prevent electrical interference or malfunction.
- Fuel Tank Filler Cap: The fuel tank filler cap must be installed before attempting to prime the system or start the engine.
- Battery Reconnection: The negative battery terminal should be reconnected, and the system should be primed by turning the ignition key to the RUN position without cranking the engine. This allows the fuel pump to run for a few seconds and prime the system.
- Fuel Pressure Test: A fuel pressure gauge should be installed on the fuel rail or supply line to verify that the system is pressurizing correctly. This step is mandatory before attempting to start the engine.
Troubleshooting and Maintenance
Even after a successful installation, it is important to understand common issues that can arise and how to address them.
- Engine Cranks But Won't Start: This can be caused by a lack of power to the pump, a failed pump, a clogged filter, or a major leak. Check all connections, filters, and the fuel pressure regulator for faults.
- Low Fuel Pressure: If the fuel pressure is below the expected range, it could indicate a faulty pump, a clogged filter, or a problem with the fuel pressure regulator. A visual inspection and pressure test can help identify the issue.
- Fuel Leaks: Any visible fuel leaks must be addressed immediately. Check all fittings, hoses, and connections for tightness and integrity. Replace any damaged components.
- Pump Failure Signs: A failing fuel pump may exhibit symptoms such as difficulty starting, stalling under load, or a noticeable drop in performance. If these signs are present, the pump should be inspected and possibly replaced.
Regular maintenance is also essential to prolong the life of the system. The sock filter should be checked and replaced every 12–24 months, depending on tank cleanliness. A post-pump inline filter should be installed if not included in the kit and changed according to the manufacturer's recommendations. Using high-quality fuel from reputable stations and storing the vehicle with a full tank of stabilized fuel can help prevent oxidation and varnish buildup.
Conclusion
The installation of the FiTech Dual Quad EFI system requires a combination of mechanical skill, electrical knowledge, and adherence to safety protocols. By following the detailed steps outlined in this guide, users can ensure a successful and reliable installation that enhances their vehicle's performance. Regular maintenance and troubleshooting can further extend the system's lifespan and prevent costly repairs. For enthusiasts and professionals alike, the FiTech Dual Quad system represents a powerful and versatile solution for high-performance fuel delivery.