procharger fuel system routing
 

I need a little help. can someone give me the correct installation of the procharger fuel system on a 98 454 mag.

trying to diagnose a fuel pressure problem and don't have the manual to see how it was routed. contacted procharger and they said they have to mail it. so now i have to wait.

where are you located

im in NJ

cant get the fuel pressure to go over 18psi messed with the regulator no change. pinched the return line no change.

maybe a bad pump

do you have stock fuel system? If so, is it cool fuel or VST. Do you have a mechanical pump mounted onto the RAW water pump

it comes from the tank into a black electric fuel pump then into the filter from there it goes under the motor to the cool fuel then into the big red regulator then tee back into the inlet of the pump.

the regulator and fuel pump i believe are aeromotive at least that what they look like

hope that makes sense

fixx
 

look brfore the pump,the fuel is soppose to be filtered before the pump..if no filter then disconnect the line going to the engine and put it in a bucket turn the pump on and see how much comes out,should be allot with in seconds so watch it..im suprised they ran that fuel pump into the cool fuel,,that pump will support 1000 hp...

got a fuel pressure update. ran the pump into a bucket alot of fuel came out.so i reconnected everything and adjusted the regulator got the pressure set to 38 but as son as you apply the throttle it drops pressure.

i still think its the pump. i found some tiny metal particals in the bucket i ran the fuel into.

any thoughts

fixx
 

i think your sopose to bypass the cool fuel with that a1000 pump,the cool fuel will never keep up with the pressure of volume of fuel needed for boost..

this is a 496 instalation manual if it helps with the fuel system..
http://www.cpperformance.com/instruc...charger496.pdf

My original fuel set-up on my 2000 502 mpi m-3sc procharged set-up used a a1000 aeromotive pump, it pushed it thru the stock cool fuel garbage and there was a piece that Procharger had you substitute into the cool fuel in place of the stock fuel pump, with the plastic cover on the cool fuel you couldn't see this and it looked like somehow they were still using the stock pump when they weren't, not sure how it possibly did it but it had no problem supporting 600 hp or so even with stock lines and all that cobbled up ****, I remember the adapter pieces in the cool fuel having little tiny inlet/outlet holes like 1/4 " or 5/16 ID. I tore it all out later when I decided to upgrade further and bought a small oil cooler to use as a fuel cooler and totally eliminated all the factory "cool fuel" crap. At that point I also added a second line feeding the stock rail. Later on in the quest to make even more hp I made twin rails and got rid of the stock single rail, Smitty

IF you kink off the return hose from the regulator your pressure will max out at whatever it can actually make , sounds like you did this already and there wasn't much there. The one thing I would do before condeming the pump is to put a volt meter on the pump when you do this and make sure you have full line voltage while maxing it out. Procharger has you wire the a1000 with those tiny little 16 gauge or so doorbell wires from the Mefi relay to run the pump, the first thing I tell guys to do with this setup is to use THOSE power wires to turn on a REAL relay (like a 30 amp or bigger) to power the fuel pump, if your voltage isn't there your pressure will be eratic and I can't imagine those stock fuel pump wires supporting more than 10 amps if even that! On my own boat I used a Bosch 50 amp relay wired with 10 gauge wire to a solid, direct power source, I have fought fuel system problems in the past with my Procharged motor too, Smitty

in an attempt to eliminate all questions i just pulled the pump and regulator to check every line from tank to rail.

what i did find was when i pulled the boost ref line from the intake to the regulator was oil. the regulator was full of oil which will certainly make it malfunction.

i pulled the throttle body and don't see any signs of oil inside the intake and just to make sure i checked the discharge side of the sc and no oil there either.

i cleaned everything and was going to reassemble and test but a big rain storm moved in so as soon as it stops i will test it out

as smitty was saying that fuel system is totally junk the way procharger and merc do it...make sure you use a aero A1000 pump, boost referenced regulator, trash the cool fuel, all filters, lines, etc...plumb with good larger line with high flow filter and a RETURN line back to the tank !!! most important...use heavy wire to relay for pump...do this and engine will live....for a while

+1 on the carb models i use a western snowplow solenoid and 8 ga wires..
oil in the regulator,,mount it so that the vacume/boost pressure line from the intake is upside down,,this way when its not under boost it will suck the line clean before the boost pressure push's it into the regulator..

i would love to re-plumb it with a return but the problem is the tank. there is only on fitting in the tank (the feed)

i cleaned and reinstalled the pump and regulator. i was able to get it working and the pressure set to 38 at idle. the issue i see now is when i apply the throttle a small amount, the pressure drops. if i abruptly hit the throttle and make boost the pressure rises like it should. but if i apply throttle no boost it falls a few pounds. the only thing is i didnt pull apart the cool fuel, injectors, or fuel rail. The pressure drops makes me think there is not enough fuel available like the pumps volume is down. I ran the pump into a bucket and it sure seemed to be moving enough fuel. God this is annoying :throw:

ALL you have to do for the fuel return line is have a fitting made and cut the hose inside the boat where you fill the boat with gas and put a fitting in with an outlet for the fuel return line can connect to. A machine shop can make you one or you can call Young Performance and talk to Eddie and he can make a nice stainless steel one that works and looks great. :coolcowboy:

you can use the fitting in the filler hose, if you can get to it or get a universal sending unit for a diesel, already has a return line fitting right there...

Or you could buy one of these Return to Tank adapters from CPPerformance. http://www.cpperformance.com/c-500-f...s-returns.aspx.
If the pump is pushing out 18psi it will still flow a lot of fuel into a bucket, but without 38psi of pressure, it isn't going to run. It sure seems like the pump has an issue but you really need to check the power with a volt meter when the pressure drops.

fixx
 

set it at 40 psi and see if that does it,,if not try 36 for chits,may be too much spring pressure on the diaphram in the regulator..also make sure the hoses going to the intake and regulator are not leaking boost pressure..your really should not see boost pressure until around 3k and up..you may also not be in the proper boost range for the regulator to do its job..

remove all vac reference lines to the regulator AND monitor the FP. I am not sure but I think the Procharger came with a FMU to increase the line pressure to about 50 PSI.

Do you have a add on FMU?