Fuel System Issues

[aleccesarenriquez]

Hey guys, long post inc:

Backstory: I recently picked up a used Paxton 2200sl kit and a used Sai Li fuel system. Kit runs great and I have no complaints. I opted for the 3.8 pulley and 93 tune for now just to familiarize myself with the power and I planned on pullying down and switch to e85 within the next few months.

Unfortunately, I ran into a few hiccups soon. After the first few days of driving it (I picked it up with a 3/4 full tank of 93), I was cruising with about a quarter tank left and all of a sudden I got a popup saying 3 miles to empty. Obviously I was alarmed, but I managed to barely make it to the station with 0 miles left. I filled up with 8 gallons and noticed that the tank now read over 3/4 full.

There seems to be something up with the crossover system, but the hat has been pulled and everything was plugged in correctly and there weren't any kinks or anything. However we did notice that the hat did not look like the one used with the Sai Li system. Here's a picture of the top of the hat: https://imgur.com/a/WxbMKiB

Here are some additional details that might help:
1. When I try to fill up completely, the linkage in the pump handle flips off before my fuel reading shows full. It tops out around 12 -13 gallons it seems.
2. I asked the original owner if he had the same issues. He says he had the same issue where it would read empty after a quarter tank. When I asked him about when they started occurring, he said that one of the pumps that came with the sai li system went out (he said it was a 267), so he replaced both pumps with 450s and he started having the issue but ignored it anyways.

If you guys have any ideas on what might be going on, I'd love to hear anything at this point lol.

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[SheepDog]

So you are saying that the tank will actually only hold 13 gallons, or it goes to "full" with 13 gallons added? It could be possible that the cross over tube that goes to the passenger side is getting tangled up with the float on the level sensor. If the tank only actually holds 13 gallons, maybe there is a few kilos of cocaine in the tank?

I just installed a Sai Li kit and it does not look like the one you have. Maybe it is one of the older kits? Or maybe its the Roadheavers kit?

The pumps themselves have nothing to do with tank capacity or the sending unit.

 

[aleccesarenriquez]

I haven't seen the fuel gauge move to full since the install. It'll only hold 12-13 gallons (the gas pump clicks and when I get in the car, it shows a little over 3/4 full), 4 of which I can't use either. So in effect, I can't use essentially half my tank. I think the fuel is just sitting there, inaccessible.

How exactly does the cross over system work? I didn't do the install and I was just told by 2 different installers that it looks like it was set up correctly. Additionally, wouldn't the same exact mistake have to have been made to the previous car as well? Seems like something is up with the assembly and not necessarily the install. Obviously I could be wrong; any insight?

I bring up the pumps because that's the primary variable in my non-working system as opposed to the typical sai li system.
Is it possible that when "fabricating" the assembly shown (it looks totally unprofessional to me), something wasn't sealed properly and one of the lines isn't able to pressurize properly? I'm just shooting in the dark here.

 

[Kona 18]

You're cross over hose is binding your fuel level arm, this is a common mistake that happens during install. The fuel pump you have is the actual gt500 one, which is why it has the vertical outlet instead of horizontal btw, so no problem there.

The easiest way to fix this is to wait ti'll you're tank is almost empty, pull the fuel pump assembly out of the car, make sure the cross over hose's 90* fitting is facing the back of the car and the hose is aimed towards the rear of the car, then lower the assembly back into the car. If there is fuel in the tank the line will sometimes float its way forward and then end up under or over the fuel level arm and will cause your fuel level to either under/over report at certain thresholds.

 

[aleccesarenriquez]

You're cross over hose is binding your fuel level arm, this is a common mistake that happens during install. The fuel pump you have is the actual gt500 one, which is why it has the vertical outlet instead of horizontal btw, so no problem there.

The easiest way to fix this is to wait ti'll you're tank is almost empty, pull the fuel pump assembly out of the car, make sure the cross over hose's 90* fitting is facing the back of the car and the hose is aimed towards the rear of the car, then lower the assembly back into the car. If there is fuel in the tank the line will sometimes float its way forward and then end up under or over the fuel level arm and will cause your fuel level to either under/over report at certain thresholds.

This all makes perfect sense. Its curious though because two reputable mechanics in the area have pulled it and placed it back and I haven’t had any luck.

Just confirming there is no other possible explanation? Anything mechanically wrong with the assembly? Seems weird that it would happen three times to two separate people but I guess if the installer is making the same mistake each time, it’s very possible.

This is some good insight though. Let me communicate this to them as well to see if they’re aware of this potentially happening.

 

[SheepDog]

If you really only can put 13 gallons in the tank, I would suspect that the cross over may not be sucking the fuel from the passenger side. Make sure the hose isn't kinked that is connected to the bottom if the pump bucket, and that the float arm isn't getting caught up with the hose. There is no pump on that side, but I believe there is a level sender.

 

[Kona 18]

Just confirming there is no other possible explanation? Anything mechanically wrong with the assembly? Seems weird that it would happen three times to two separate people but I guess if the installer is making the same mistake each time, it’s very possible.

Doesn't matter how good the mechanics are, what's happening isn't because they don't know how to remove the pump and put it back in, but bc the hose prob floated it's way forward and is binding the arm. When you install the pump assemble you can't actually see the hose, they may have aimed it in the right direction both times but once you start to lower it into the tank you can't see it anymore and it can point itself forward instead of backwards. Doing the swap when you are really low on fuel, like 5 to empty is usually best

 

[aleccesarenriquez]

Doesn't matter how good the mechanics are, what's happening isn't because they don't know how to remove the pump and put it back in, but bc the hose prob floated it's way forward and is binding the arm. When you install the pump assemble you can't actually see the hose, they may have aimed it in the right direction both times but once you start to lower it into the tank you can't see it anymore and it can point itself forward instead of backwards. Doing the swap when you are really low on fuel, like 5 to empty is usually best

One more question: What do you think is going on with that glue stuff surrounding one of the ports. Could modding the housing like that cause issues? One of the mechanics thinks that a modified hat like that would compromise the whole system and is suggesting I just get a fore fuel system.

 

[Kona 18]

One more question: What do you think is going on with that glue stuff surrounding one of the ports. Could modding the housing like that cause issues? One of the mechanics thinks that a modified hat like that would compromise the whole system and is suggesting I just get a fore fuel system.

long as it doesn't leak leave it alone. Normally you would use a 6an bulkhead fitting with a PTFE washer, but maybe that kit he didn't? IDK, only Sai himself would. Bt if it's not leaking leave it as is

 

[5point0anthony]

Did you ever find the fix to this?

 

[aleccesarenriquez]

Did you ever find the fix to this?

Yep. Bought Fore

 

[5point0anthony]

im having the same issue with another brand fuel system

 

[aleccesarenriquez]

im having the same issue with another brand fuel system

Is the fuel hat modified? Have you ever replaced the pumps in it?

 

[FastCarFanBoy]

You can’t put Walbro pumps in the factory hat setup because they lack the Venturi ports that create the siphon to get fuel from the passenger side tank. You have to either run stock pumps or upgrade with DW400’s and modify the bucket to accept the 400’s which is what I did. You can use the DW fuel hat with walbros and keep the factory bucket.

 

[TGGT]

You can’t put Walbro pumps in the factory hat setup because they lack the Venturi ports that create the siphon to get fuel from the passenger side tank. You have to either run stock pumps or upgrade with DW400’s and modify the bucket to accept the 400’s which is what I did. You can use the DW fuel hat with walbros and keep the factory bucket.

not true. I’ve been running 2 walbro 465’s for months in a gt350 hat with zero problems. They siphon just fine.

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