Modern EFI systems are designed as much as possible to be a direct bolt-in upgrade from carburetors. Installing them typically requires relatively few changes from what originally came with the vehicle back in the day. But one aspect that does need special attention when upgrading to EFI is the fuel system.

EFI systems need a steady supply of fuel at constant pressure to function properly. To achieve that, there are two general choices of fuel system – returnless and return-style. A returnless fuel system uses one line to deliver fuel from the tank to the engine and relies on the ECU to control the pump and vary pressure as needed. In this type of system, fuel doesn’t return to the tank.

A return-style fuel system has two lines running from the tank to the engine. One line delivers fuel to the engine at a constant pressure suitable to meet all possible demands. The other line returns to the tank any excess fuel that isn’t needed in a particular driving situation.

Returnless fuel systems are easier to set up. They don’t require you to run a second fuel line and create an attachment for it at the top of the fuel tank. But returnless systems are somewhat more prone to vapor lock, they require an in-tank fuel pump, and they’re not as responsive to the widely varying demands of extreme high-performance applications.

In contrast, return-style fuel systems are less prone to these issues and are therefore generally more suitable for high-performance vehicles. They do, however, require additional work to set up. The simplest way to prepare a vehicle for a return-style fuel system is by purchasing an EFI conversion fuel tank, which has the return inlet already installed. They’re available for a wide range of vehicles and they’re relatively affordable considering the amount of work they save you.

That said, conversion tanks aren’t available for all makes, models, and years of vehicles. And, although these tanks are priced well within reach of many enthusiasts, some car owners nonetheless require a lower-cost alternative for getting the job done. If either of those are the case, you’ll need to install a return fuel inlet on your existing fuel tank.

Up to this point, the only way to do so was to weld the necessary fitting onto the tank – which can be a problem for those who lack the necessary equipment and skills. Fortunately, Earl’s Performance Products has now developed a simple fuel-return solution that doesn’t require welding.

An Easier Way

Earl’s weldless fuel return kit makes it easy and quick to add a fuel return line. It works on any steel or aluminum fuel tank that has a flat, horizontal surface on top and is 1/8” thick or less. The unit’s low-profile design allows it to be installed in a wide range of different car and fuel tank combinations, including those with limited clearance. It’s machined from high-quality 6061 billet aluminum with a knurled and ribbed body that helps prevent rotation. All the components are suitable for pump gas and E85.

The kit includes fixed and flexible in-tank fuel return tubes, with 6AN ORB plug and installation hardware. It can also accommodate 6AN, 8AN, 5/16” or 3/8” hose barb adapters (sold separately). The integrated 3/8” hose barb feature effectively routes returning fuel below surface level and eliminates overhead splash.

Installation is simple. You basically just drill a hole in the top of the tank, install the return tube, insert the fitting with the rubber washer, and tighten the bolt. The fitting collapses or “mushrooms” from the underside which secures the fitting from the inside.

So, no matter what kind of vehicle you’re upgrading to EFI, Earl’s new weldless fuel return kit makes it easy, quick, and inexpensive to set up the return-style fuel system you need to complete the job. It’s simple enough that even complete novices can do it, and you don’t need a welder or any other specialized tools.

Click Here Now to see Earl’s weldless fuel return kit