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The Stage II fuel system is a regulated return system designed for all applications. This is a full flow, full power, no scrimping kit. We basically reroute and have redesigned the factory fuel system. Our Stage II kit is designed to work with the Stage I kit and Stage I is included in this price.
The factory fuel system is designed that 100% of the fuel is sent to the fuel filter housing that sits on top of the engine. From there, is it is pressurized and filtered. Once filtered, the fuel is sent to the front of the cylinder heads through a restrictive banjo bolt with a one way check valve. Once the fuel is in the cylinder it is there until it is injected into the cylinder by the injector.
This is a good sound system from the factory. They have designed a system that works for the most port within their tolerances. This system will last for a very long time with no soft lines. The draw backs of this type of system is that if air gets into the cavity, it has to be sent through the injector to be released, the back injectors can run low on fuel pressure because of demand (the last injector sees the fuel last), and the fuel stays in the cylinder head heating up until it is used).
Our system works a little differently. We cap off the fuel return line at the fuel filter housing. This causes 100% of the fuel pump to go through our Stage I fuel kit (Click here to read about it). Once the fuel has entered the cylinder head, it has two options. One, be injected by the injector and two to go out the back side of the head and up the new large Stainless Steel tubing that is now in the back of the head. From there, the fuel is directed though the tubing and though a stainless steel braided fuel line and to an Aeromotive fuel pressure regulator. The Aeromotive fuel pressure regulator then regulates the fuel pressure (after the injectors) and sends the excess back to the fuel tank.
We have spent a lot of time researching parts and designing the right components. There are a few regulated return kits on the market and most use soft line (steel braided or not) on the back side of the heads. We have not found a single flexible line (steel braided or not) that is rated for the heat produced by the up-pipes and would strongly recommend you consider this before choosing a kit. After all, if a line fails, it generally leaks. Who wants fuel leaking on their hot up-pipes? The remaining kits use smaller stainless steel tubing to return the fuel from the back of the cylinder heads and then use a larger line to continue onto the regulator. We use the same size tubing and stainless steel braided lines start to finish on the engine. No compromises, no expense spared.
As with our Stage I kit, all fittings in this kit feature either o-ring seals or washers. No Teflon tape is needed during installation. All fittings are adjustable allowing the fuel line to naturally run without binding or putting pressure on the fitting, which could cause failure.
We designed these kits with the highest quality and ease of installation possible. The Stainless Steel Tubes that are mounted on the back of the head are a perfect example of that. Instead of using a banjo bolt with two washers (one for each side of the fitting) we designed this kit to use an o-ring on the inside of the fitting. This means that when the person is installing this kit reaches over the engine and is feeling for the hole on the back side of the head, he doesn’t have to worry about the washer sliding off the end of the banjo bolt (a very common problem).
Again, this kit doesn’t sacrifice quality or reliability. We don’t believe in that! Our fuel lines all come with a 50 year warranty against defects, leaks or anything else that comes up. The only exception is if the lines get cut, pinched and/or damaged by user error. The Aeromotive regulator comes with a 2 year manufacture warranty.
Please note: The Stage I Fuel Kit is not compatible with trucks equipped with a dual alternator setup.
Trucks equipped with aftermarket intercoolers with oversized tubing may have interfere issues.
The fuel line that we use is the standard for the automotive industry. It is made up of two different layers. The inner layer is extruded Teflon® and the outer layer is stainless steel braid. This is the ONLY line that is designed to handle diesel fuels, additives, Bio-diesel, Waste Vegetable Oils (WVO) and all additives known to us. (Teflon® is a registered trademark of DuPont Performance Elastomers.)
Installation instructions
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