Consult you Greasecar manual for the proper routing. This car has a lift pump so follow the appropriate directions. This description is just more detailed than Greasecar. If you really understand the car and the kit well you won�t need this help. The pictures may help for identification of specific components. The final picture of the fuel lines is impossible to follow.
Remember to replace the banjo bolt on the fuel filter.
Plan
Identify the following locations in the car.
Lift Pump � Right side of motor. It has two ports, one in and one out.
Injection Pump Port - To the left of the lift pump. See Lift and Injection Pump picture below.
Diesel Filter Ports - See Diesel Filter Back and Diesel Filter Side pictures below.
Diesel Filter In Port - There are arrows on the top of the housing pointing the flow direction.
Diesel Filter Out Port - There are arrows on the top of the housing pointing the flow direction.
Motor Fuel Return Port - From the motor to the diesel filter.
Diesel Filter Fuel Return Port - from the fuel filter back to the tank.
Diesel Fuel Return Hose (It goes to the diesel tank. It is also the other end of the Diesel Filter Fuel Return Port) See Diesel Return picture.
Diesel Supply - Line going into the Lift Pump.
Veggie Supply (PEX sticking out of the fitting)
Veggie Filter In � Refer to the arrows on the veggie filter cap
Veggie Filter Out � Refer to the arrows on the veggie filter cap
Label all the solenoid valves if you did not already do so. Use Greasecar manual to determine each port.
Fuel Supply Valve
Veggie Supply Valve Port
Diesel Supply Valve Port
Common Fuel Supply Valve Port
Fuel Return Valve
Veggie Return Valve Port
Diesel Return Valve Port
Common Fuel Return Valve Port
Remove Existing Fuel Hoses
Clear Hose
The clear hose is hardest to remove. Both of the clear hoses can be seen in the Diesel Filter Side picture. Cut the clear hose so there is 3 inches remaining past the barb (enough to grab hold of). Lightly scored the hose over the barbs. Be careful not to cut all the way through. Put a slit down the length of the hose extending � inch from the end of the barb. Carefully tear the hose off the barb.
Black Rubber Hose
Remove the clamps and pull the hose off. Save clamps and reuse where possible.
Re-Plumbing the Fuel Lines
Leave enough hose length to allow the removal of the veggie filter without disconnecting any hoses. Most fuel lines will be 5/16�. The rest will be ��
Connect the following:
Veggie Filter In to the Veggie Supply (PEX).
Fuel Supply Valve
Veggie Supply Valve Port to the Veggie Filter Out Port
Diesel Supply Valve Port to the Diesel Filter Out Port
Common Fuel Supply Valve Port to the Lift Pump Port
Fuel Return Valve
Veggie Return Valve Port �Tee into the line between the Veggie Filter In and the Veggie Supply..
Diesel Return Valve Port to the Diesel Fuel Return Hose
Common Fuel Return Valve Port to the Diesel Filter Fuel Return
Lift Pump Out to the Injection Pump. Can be seen in the Fuel Supply Fitting picture behind the fitting.
Diesel Supply to the Diesel Filter In Port -The lines from the Diesel Supply to the Diesel Filter In is where I used the transition piece. Screw the �� barb male into the 5/16� female. Install clamps on the barbs.
Diesel Filter Out to the Diesel Supply Valve Port - The other �� hose will run from the Diesel Filter Out to Diesel Supply Valve Port. The diesel filter cap has in and out arrow marking the ports. I was able to push the �� hose on the 5/16� valve port. I used a little veggie oil on the hose as lube to help it on..
Tank Level Sensor Gasket
I used a solid gasket to seal the level sensor to the tank instead of the tube of sealant supplied by Greasecar. This allows me to open the plate and see inside the tank better if I need to (which I have needed to).
