Modern Factory Fuel Pump Module

[EricLar80]

Has anyone ever adopted a modern, in-tank fuel pump module to their Bronco fuel tank for EFI? I have been doing a little bit of research and a fuel pump module from a 1998 Chevy Silverado looks like a great candidate, something like DELPHI FG0085 (see picture below).

You can get these pump modules relatively cheap ($100-150), they have a built-in sender (will only work with 250-40 ohm gauges), simple supply and return connections, and a nice o-ring seal. Best of all, the factory quality pumps have what is called a jet-pump built into it - this is a device that keeps the bucket for the pump full of fuel. The jet pump is why factory pumps are so reliable, and why you can run modern cars almost to empty without fuel starvation. The pump also runs cooler and is muffled because of the the bucket of fuel.

I'm looking at the Chevy pump for having a return line and no emissions add-ons, and were used on V8s up to 454ci. They are about 15-16 inches tall and will compress to fit firm to the bottom of the tank, so they should match a 23 gallon Bronco tank well.

I also found this adapter that can be welded to the tank to make the factory o-ring work:

 

[ransil]

I pulled a bunch of fuel assemblies from the junk yard years ago, best fit at the times was the 96 +/- explorer but it had a fixed depth but had a bolt in ring at the top so that why I thought best fit.

The chevy ones looked good due to the compression but the top sealing with the 'big nut" was not possible, looks like that bolt down ring will do the job, Aftermarket gauge should be easy to get.

If building a tank I would build it with a recess for the sending unit to sit flush at the top of the tank so the tank can be up as high as possible.

 

[sanndmann3]

I did something very similar but with a sender from Mercury Villager I think. Modified the stock Bronco tank to accept it, including shortening the rods so it would fit. Jet pump feature works really nice.
Wish I knew about the Silverado pump and adapters a few years ago. would have saved me some time and effort.

 

[bmc69]

I modified the length of an in tank assembly to make it the right depth for my custom tank. I just perused those available until I found one that looked close enough to start with.

 

[wsager]

I have considered that pump, but thought I would have to get the ring from a donor tank. I wasn’t sure if the psi would be high enough for the explorer returnless system, but I did find that they sell upgraded pumps for that setup. You should try it and let us know how it works. What engine setup are you going to run?

 

[Broncobowsher]

Most all of the modern ones I have worked with (in the past 20 years anyway) have all been spring loaded. That is because the plastic tanks flex and move around with heat and the weight of fuel. The fuel chamber with the jet pump on the return port is slick. The fuel pump sits in a mini fuel tank that is always full and overflowing. solves the fuel slosh/accumulator issues.

But the install has always been an issue. Every one is different. Usually some proprietary sealing system that was designed for the factory worker to quickly install the pump. That is the first aftermarket install ring I have seen. It looks rather crude. 2 flat plates with 4 welded studs. I don't see an O-ring groove.

 

[bmc69]

I mounted the pump support bracket to a flat plate. Sender is separate because I wanted to keep the stock EB guage.

The pump sits in a square "box" that roughly 4" tall and has only a couple very small holes in the bottom edge of the sides to allow gas to fill it when the top of the box is above the gas level in the tank.

 

[EricLar80]

But the install has always been an issue. Every one is different. Usually some proprietary sealing system that was designed for the factory worker to quickly install the pump. That is the first aftermarket install ring I have seen. It looks rather crude. 2 flat plates with 4 welded studs. I don't see an O-ring groove.

There is another version that has a flat plate that can be welded to a tank, but it’s not needed since ours have a flat, smooth top. The o-ring seals between the top of the Bronco tank wall and the pump. Sealing isn’t dependent on the quality of the weld job, which is nice.

The way it works is our tank would have a hole cut in it just large enough for the pump to fit into. Then the ring with the studs is welded on top in a few spots. The o-ring sits inside the inner diameter of that ring and against the top of our tank. The top ring compresses the pump against the pump housing to the o-ring and holds it all in place.

 

[EricLar80]

I mounted the pump support bracket to a flat plate. Sender is separate because I wanted to keep the stock EB guage.

The pump sits in a square "box" that roughly 4" tall and has only a couple very small holes in the bottom edge of the sides to allow gas to fill it when the top of the box is above the gas level in the tank.

It looks great! I’m curious why you chose to recess the fill and vent tubes?

 

[EricLar80]

I have considered that pump, but thought I would have to get the ring from a donor tank. I wasn’t sure if the psi would be high enough for the explorer returnless system, but I did find that they sell upgraded pumps for that setup. You should try it and let us know how it works. What engine setup are you going to run?

You could have gone to 2004+ system that is returnless as well. I think it may operate at the same 65 psi as the explorer.

 

[DirtDonk]

It looks great! I’m curious why you chose to recess the fill and vent tubes?

Guessing for two related reasons. Ease of installation with a tank that's as wide as the frame rail opening, while still being able to get full hose coverage and clamping.

Paul

 

[suckerpunched]

i think its a good idea, i would like to build my own tank on my next bronco. if you want to use the original style gauge, there is this,

http://www.yogisinc.com/index.cfm/p...16424/category_id=3725/mode=prod/prd16424.htm

 

[toddz69]

How does the jet pump work?

Todd Z.

 

[EricLar80]

How does the jet pump work?

Todd Z.

A 2nd, smaller outlet on top of the primary pump sends high pressure flow through a Venturi that collects a fuel from the tank. The cool thing is that it will scavenge nearly every last drop in the tank without damage because it has no moving parts to jam up. Here’s a demonstration of one filling up a reservoir.

www.youtube.com/watch?v=qDV1pY65Sfk

Even cooler, it could be used to bring fuel from a 2nd tank. They use it to bring fuel from 2 sides of the same tank when the tank is bisected like a saddle.

NOTE: some aftermarket pumps don’t have the jet pump. You need to buy a quality, OEM grade unit. It can be identified as having a a smaller tube the loops back down towards the bottom. This picture has a good view.

 

[toddz69]

Very interesting - learn something new every day!

Todd Z.

 

[Broncobowsher]

How does the jet pump work?

Todd Z.

Venturi and a duck bill check valve. The return flow squirts through a hole and the velocity sucks up surrounding fuel. To an extent, the same as a suction sand blaster or venturi vacuum pump. The fixed pressure fuel pump module with the built in pressure regulator makes for things being really simple and self contained.

 

[bmc69]

Guessing for two related reasons. Ease of installation with a tank that's as wide as the frame rail opening, while still being able to get full hose coverage and clamping.

Paul

Spot on.

 

[EricLar80]

Spot on.

Ah, so the tank is wider than normal, fitting closely to the width of the frame rails?