The original fuel pump, pressure regulator, and bypass hose are submerged inside the tank, and the fuel system only has a single hose to the injection system on the engine.
The pump itself isn't rated for diesel or biodiesel, and I want to install a recirculating fuel system with an external pump and separate fuel return line to the tank, so it was necessary to dismantle the stock components and make modifications.
I started by removing the fuel pump and regulator assembly from the sending unit, and pulling the pump wires out of the bulkhead fitting. I sealed the holes in the bulkhead with marine epoxy, spliced the pump wires to a 6ft extension, and coiled them up for later use with an external pump.
I replaced the fuel pump and regulator with a custom pickup tube made from the following components:
- 3/8" ID SAE30R10 Submersible Fuel Line (6")
- McMaster-Carr P/N 5357K36 - 3/8" Barb x 1/4" MNPT Hose Fitting
- McMaster-Carr P/N 1610T14 - 6061 Aluminum 1-3/4" Dia, 3" Long
I turned the aluminum bar on a lathe to surface and chamfer the ends, then drilled a 3/8" through-hole and tapped to 1/4" NPT on one side.
The turned aluminum bar fits into the space vacated by the submerged pump, and is secured by the stock clamp. Once completed, I reinstalled the modified sending unit in the tank.
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