NOTE: This kit contains installation parts for different vehicle types
Quantity and Description of parts kit
(Fig.1) 1–EZ-FUEL ready to mount, quick
connect
plastic (QCPE) enclosure (pre-fitted with
quick
connects)
(Fig.2) 1 coil of 5/32 ID X 6 foot -
vacuum hose (black)
(Fig 3) 1 coil of 1/4 ID X 7 foot - high
pressure fuel
supply hose (yellow)
(Fig.4) 1 Schraeder
valve removal tool
(Fig.5) 1 Ford test port
fitting
(Fig.6) 1 GM/ Chrysler/Jeep test port
fitting
(Fig.7) 1 Flat toggle plate bracket for
QCPE
(Fig.8) 1–90 degree angle bracket for
QCPE
(Fig.9) 1– Universal fuel Line T-fitting 3/8x1/4x3/8
O.D.
(Fig.10) 1–Universal fuel line T fitting 5/16 X 1/4 X
5/16
(Fig.11) 1–Universal fuel line T fitting 1/4x1/4x1/4
O.D.
(Fig.12) 1–Vacuum line T-fitting
(Fig.13)
1–Vacuum puncture fitting
(Fig.14) Allen
wrench
(Fig.15) 4–1/4-16X 2” bolts
(Fig.16) 1/4- 16 X
3” bolts
(Fig.17) 4–1/4-16 X 4 “ bolts
(Fig.18)
4-sets–1/4-16 X 1” bolts with nuts and washers
(Fig.19) 4–3
inch pieces of split scuff guard
(Fig.20) 4–1/4 X 1 inch,
Self drilling bolts
(Fig.21) 1–In-line shut-off
valve
(Fig.22) 6–Stainless steel hose-clamps
(Fig.23)
12–Cable ties
(Fig. 24) - Scuff guard
SECTION A
Installing the EZ-FUEL, Quick Connect
Plastic Enclosure (QCPE)
The QCPE (Quick Connect Plastic Enclosure) (Fig. 1) can be installed anywhere under the hood where it's safe or almost anywhere on the outside of the vehicle.
The mounting brackets (Fig. 7 & Fig. 8) are designed to allow a variety of possible configurations. The holes and slots allow for total flexibility in the many possible mounting locations and combinations. Combined with the various length bolts (Fig. 15, 16, 17, 18) and the self tapping screws (Fig. 20) there should be little problem in finding a suitable bracket / mounting combination.
The mounting brackets (Fig. 7 & Fig. 8) and QCPE (Fig. 1) have the exact same mounting holes and slots, However, the QCPE (Fig. 1) has none of the holes or slots drilled. Therefore, you will need a 1/4 inch drill bit to drill the holes through the enclosure to mount it.
If you are using self tapping screws (Fig. 20) you will need a 5/16 nut driver for your drill. Use the flat toggle bracket (Fig.7) to check for placement / alignment of the through the grill mounting location.
Note: there should be sufficient
clearance for the hoses that attached to the back of the QCPE. There
should be enough clearance for the hoses to pass through the grill
and then make a gentle bend so as to not kink them. Make sure the
hoses do not rub on any of the behind the grill components. Do not
allow the hoses to touch the spinning pulleys or belts. Route all
hoses away from any hot engine surfaces, especially the exhaust
manifolds.
Tip: uncoil the two supplied hoses in advance. This
will straighten them and make an easier
installation.
For most of the under-the-hood installations the QCPE (Quick Connect Plastic Enclosure) (Fig. 1) is usually mounted in a horizontal position. For example, the 90 degree angle bracket (Fig. 8) could be mounted onto a fender well using the self tapping screws (Fig. 20) with the angle bracket (Fig. 8) facing up. For this you would use the 1/4- 20 x 1 1/2” bolts ( Fig. 18). to attach the enclosure after the angle bracket (Fig. 8) is installed. The flat toggle bracket (Fig. 7) may be mounted in an off set position and the QCPE to it.
To install QCPE on bumpers, bed-rails
or other level surfaces mount the QCPE in a vertical position using the
90 degree angle bracket (Fig. 8) (See Picture 1).
The QCPE can be grill-mounted on most vehicles. It may be necessary to remove the grill from the front of your vehicle or loosen it to facilitate installation. Using the correct length 1/4 - 20 X 1 1/2” ,or 2”, or 3”, or 4” bolts and the flat toggle plate (Fig. 7). This type of mounting is known as a sandwich mounting. In this case the grill of the vehicle is sandwiched between the QCPE and the flat toggle plate using up to four of the 1/4 inch bolt sets.
Besides accurately positioning the bolt locations, a clearance needs to be given to the hoses and hose clamp that also pass through the grill. In some circumstance only two or three of the through bolts will line up to pass between the grill slots. This will be sufficient, as long as the location of these bolts are spaced at opposite sides of the QCPE. As a last choice the self tapping screws (Fig. 20) may be used and will in fact eliminate the need for the flat toggle plate to be used as a sandwich plate on the back of the grill. When using the self tapping screws, adjust the slip clutch to "low" on your screw gun so as not to strip the holes out after the screws bottom out. This is not necessary when drilling and self tapping into steel verses the plastic grill.
Step 1: Grill mounting
Start by holding the
flat toggle plate (Fig. 7) in front of the grill to locate the
correct mounting holes or slots. while allowing both the hoses and
mounting bolts to pass between the grill slots. Thought should
be given to have clearance behind the grill so as not to bend the
hoses so tightly as to cause them to kink. A piece of the scuff
guard (Fig. 24) should be cable tied (Fig. 23) to the fuel supply
hose if it rubs against the radiator or any other components. Note
that all of the holes and slots in the flat toggle plate (Fig. 7)
and even the 90 degree bend plate (Fig. 8) all line up precisely
with the support plate located inside the back of the QCPE.
Step 2: Locate the holes
Use the flat toggle
plate (Fig. 7) as a template to identify the QCPE mount location.
Using a marker, mark the location of where you would bolt the flat
toggle plate with the through bolts.
Step 3: Transfer marks
Transfer these marks
to the inside of the QCPE bracket. Double check your marks.
Step 4: Drill holes
Drill four 1/4" holes
through the back of the plastic to match the marked holes in the
toggle plate.
Step 5: Test assemble onto grill
Using the
correct length bolts test assemble the two components onto the
grill. Tighten the nuts and bolts hand tight and check if there will
be adequate clearance (3 inches) behind the grill.
Step 6: Disassemble
When you are satisfied
with the hole locations and are sure that there is sufficient room
between the grill slats for the hoses to pass through, disassemble
the enclosure.
Step 7: Connecting hoses to the
QCPE.
There are two coiled hoses that are supplied
in your installation kit, one black (Fig. 2) and one yellow (Fig.
3). On the back of the QCPE there are two hose barbs that protrude.
The fuel supply barb is the larger of the two and the vacuum / vapor
recovery is the smaller. The yellow fuel supply line is fairly
difficult to press onto the hose barb without a lubricant being
applied. We recommend any type of motor oil (can be wiped off of
your oil dipstick as a last resort) and the fuel supply hose will
always be secured with the hose clamps. These clamps will always be
tightened to snug. (Suggestion: In cold weather - warm up the end of
the yellow fuel supply line in cup of hot water - this will make the
hose more flexible and easier to install). The yellow supply hose
(Fig. 3) must be pushed onto barb till it's fully seated. The
vacuum/ vapor hose (Fig. 2) is an easy push on and doesn't need hose
clamps. The fuel supply hose is fairly rigid and needs to be routed
to avoid kinking as this will impair fuel flow. The yellow fuel
supply hose should always be routed away from any hot engine or
exhaust manifold surfaces. Lubricate the large hose barb and the
inside tip of the yellow fuel supply line and push it firmly onto
the barb until fully seated. Use one of the supplied hose clamps to
secure the yellow fuel supply line to the 1/4” hose barb located on
the back of the QCPE. Then push the black hose onto the smaller hose
barb until fully seated. Always use scuff guards to prevent the
yellow fuel supply hose from rubbing against any sharp edges.
Step 8: Mounting to the grill
For vertical
mounting on angled grills the 90 degree bend angle bracket (Fig. 8))
may be installed between the back of the QCPE and the grill, thus
flattening the QCPE. This angled plate should be installed with the
bend opening facing toward the back of the QCPE in order to adjust
the QCPE to be perpendicular to the ground. For work vehicles a
simplified mounting can be achieved by using the self tapping screws
to screw the QCPE directly to the grill. Note: this will leave small
holes if and when the system is de-installed.
SECTION B
Connecting the fuel lead
Vehicles with fuel system test ports:
Step1: Locate the fuel system test port
The fuel system test port is found on the fuel
rail (Picture 2). The fuel rail is easily identified as it provides fuel
to the individual fuel injectors and usually wraps around the top or crosses
over the engine above the fuel injectors / intake manifold.
Step 2: Preparing the test port for
connection
Once the fuel rail test port is located
unscrew the dust cover and use the tire valve (Fig. 4) stem remover
to unscrew and extract the valve core from the test port. (Note:
residual fuel pressure may exist to cause some fuel spray. Make sure
to ware the provided safety glasses). Depending on your vehicle
type, compare and then install the appropriate fuel lead adapter
(Fig. 5 & Fig. 6) on to the test port. Save both the dust cap
and the valve core because you may want to reinstall the EZ-FUEL
system onto your next vehicle.
Step 3: Route the yellow fuel
Route the
yellow fuel supply hose from the previously installed QCPE to the
test port. Keep the fuel supply hose at least seven (7) inches away
from any hot engine surface and secure it to adjacent hoses or
support brackets with the cable ties. Use the scuff guard provided
to protect the yellow fuel supply hose from any rub spots. Cut the
scuff guard as necessary and use the cable ties to secure the
scuff guard to the yellow fuel hose. Sufficient hose is provided for
safe and efficient routing and a small amount of slack should be
provided between the engine and the first cable tie as to allow for
some engine movement.
Step 4: Location of the in-line shut off
valve
The shut off valve (Fig. 21) should be placed in
an easy to access location. You may want to manually shut off the
system (For example, if a front end collision ripped off the QCPE /
hoses causing a leak).
Step 5: Connecting to the test port
When you
are satisfied as to with your routing then and only then should the
yellow fuel supply hose be lubricated and installed onto the test
port (or T fitting, see non-test port install). Do not forget to
first install the hose clamp onto the hose before it is pushed onto
the test port adapter. Lubricate the end of the fuel supply line and
hose barb. Slide a hose clamp over the yellow fuel supply hose and
insert it completely onto the test port adapter. Then tighten, but
do not over tighten the hose clamp.
Step 6: Installing the in-line shut off
valve
Once you are comfortable with the fuel supply line routing
and have chosen a location for the in-line shut off valve (Picture 3), cut
the yellow fuel supply hose and install the emergency fuel shut off valve
using the supplied hose clamps. (Note: lubricate barbs and hoses before
installing) The in-line shut off valve should be supported with a couple
of cable ties to support its weight. We recommend locating the in-line shut
off valve parallel to another hose or component inside of the engine compartment.
This valve should be installed where it is reachable from the front of your
vehicle. Their should be more then sufficient hose available for optimum
hose routing as the shut off valve itself will take up space. The in-line
shut off valve is provided in case there is damage to the quick connectors
and there is leaking fuel. In that case the shut off valve lever should
be rotated perpendicular to the valve which will shut off the fuel flow.
It is not necessary to close this valve between EZ-FUEL uses, as the system
is designed so that gasoline cannot be siphoned from the system while the
vehicle is parked.
Vehicles without fuel system
test ports:
NOTE: If you are not capable of performing this part
of the installation do not attempt it yourself. Bring your vehicle
to an auto repair professional to complete the
installation
Step 1: Locating the fuel supply line
Locate
the fuel system inlet hose, which is one of two hoses connecting to
the fuel rail. Some of the fuel supply systems only have one hose to
the fuel supply rail, this makes locating it easier. If there are
two fuel supply hoses the inlet hose is usually the larger of the
two. It is also the hose that is connected between the fuel
injection rail and the fuel filter. If you are not sure consult with
your vehicles shop manual or consult with a professional auto
mechanic.
Step 2: Cutting the line
Wrap this line with
some paper towels or other absorbent materials. (Note: Make sure to
wear the provided safety glasses). Cut the fuel inlet line and
install the “T-fitting” adapter.
Note
this line will have a small amount of pressurized gasoline in it. Do
not perform this step with a hot engine; use rags to collect and to
wipe up any spilled gasoline.
Chose the proper "T"
fitting by comparing it with the fuel inlet line internal diameter.
There are three fuel tees provided for 1/4, 5/16 and 3/8 fuel supply
lines. It should be a snug fit and you will need to lubricate the
fuel "T". Use the stainless steel hose clamps to secure the "T"
fitting into the fuel line you just cut.
Note: the hose clamps should be slipped over the fuel
hose before the hoses are pushed onto the hose barbs. Point the
center barb of the "T" fitting in a direction that will allow for an
interference free routing of the EZ-FUEL Yellow fuel supply hose.
Lubricate the hose and hose barb, then slide a clamp over the Yellow
fuel supply hose. Push it fully onto the "T" fitting, locate and
tighten the stainless steel clamp tight.
Remember you
are inserting the upper stems of the “T” fitting into both ends of
the cut fuel inlet hose. Install the EZ-FUEL lead onto the leg of
the “T” and secure all connections with the stainless steel hose
clamps, tighten tight. Follow the installation instruction for Hose
Routing from the test port installation section.
SECTION C
Connecting the vacuum hose
Step1: locate a vacuum supply
This connection
is made into any vacuum hose containing manifold vacuum. The easiest
way to check for manifold vacuum is to follow the vacuum line into
the intake manifold. Any vacuum hoses that connect to the intake
manifold after the throttle body will provide engine vacuum.
Step 2: Connecting to the vacuum
Cut the
vacuum line and insert both stems of the vacuum “T” (Fig. 12)
into the vacuum hose, no hose clamps are needed. Safely route the
vacuum hose (Fig. 2) from the back of the QCPE through the engine
compartment to the installed vacuum "T" fitting. Insert the vacuum
lead from the EZ-FUEL adapter into the leg of the “T”.
Step 3: Connecting to the PCV hose
An
alternative vacuum connection point and for most General Motors cars
is to puncture the large vacuum hose that connects to the PCV valve
(located in one of the valve covers) to the engines intake system.
First drill a 1/8” hole in the rubber hose above the PCV valve. Push
one end of the puncture fitting (Fig. 13) into the hole and install
the vacuum lead from the EZ-FUEL adapter (QCPE) onto the opposite
end of the union, no clamps required.
SECTION D
Checking the installation
BEFORE YOU START THE ENGINE CHECK THAT
NEITHER THE YELLOW FUEL SUPPLY HOSE OR
THE BLACK VACUUM HOSE
TOUCH ANY MOVING PARTS SUCH AS PULLEYS-BELTS NOR ARE THEY TOUCHING
OR ARE CLOSE TO (closer then seven inches) THE ENGINES EXHAUST
MANIFOLDS, RADIATOR or FAN.
Wipe any spilled gasoline from the engine, if previously disconnected carefully reconnect the battery with the ground lead being the last lead to reconnect. Then with the help of a friend start the vehicle and immediately inspect for any fuel leaks at the test port, fuel line "T", in-line shut off valve, or at the back of the QCPE.
Let the engine idle for 5 minutes, while examining all of the fuel connections for any signs of leakage. If the installation instructions are followed correctly there should be no sign of any fuel leakage. If a fuel leak is detected shut off the engine immediately. Correct the problem and repeat the inspection process until no leakage exists. Check vacuum connections for leakage and correct as needed.
SECTION E
Purging the air from EZ-FUEL
System.
Note: The EZ-FUEL system can not function unless the engine is running.
Step 1: Open the EZ-FUEL carrying case, remove the safety nozzle and hose assembly, put on your safety glasses and proceed.
Step 2: Start the engine and let it idle.
Step 3: Connect the dispensing hose assembly to the QCPE. Note that the hoses are coded male female and cannot be incorrectly installed. The vapor recovery hose uses a simple push to connect connector. The fuel supply hose (yellow) uses a retractable outer sleeve connector. To properly connect the fuel supply connector, firmly retract the outer sleeve and while it's retracted push it firmly onto the fuel barb that is in the QCPE. Do not let go until till the female connector in your hand is fully engaged with the male vehicle side connector. Don't worry if you have to repeat this, once you get the hang of it, it will be effortless thereafter. Occasionally spraying the connectors with WD-40 will insure easy connections with a long life for the connectors.
Step 4: Purging the air out of your EZ-FUEL system, this is a one time operation. To purge the air from the fuel lines, pick up the fuel nozzle, insert the nozzle tip into a suitable tank or vessel and depress the side safety interlock, while squeezing the fueling lever very slowly. The lever is designed to travel well past the safety before fuel flow will begin. This feature allows for a one handed fueling operation. Should the lever be released or the nozzle dropped the safety interlock will re-engage immediately causing the lever to be inoperable. Purging air from the system may cause the engine to stall. If this happens, re-start the engine and continue. When all of the air is purged from EZ-FUEL System, it is now time to adjust the flow adjuster to allow for maximum fuel flow. Note: for absolute-maximize fuel flow - we suggest that you start with a new OEM fuel filter.
SECTION F
Adjusting the fuel flow
Note: This step is also performed only once
Step 1: Locate the 5/32 inch Allen wrench (Fig.
13). You will need it to adjust your fuel flow.
Step 2: Start by removing the flow adjuster dust plug located under the vapor recovery (yellow) bellows on the front of the fueling nozzle (Picture 4). You will see the Allen fitting, this is the flow adjuster which is pre-set at a "low" flow rate from the factory. The EZ-FUEL fuel nozzle has a safety lever interlock which must be released before the nozzle lever can be squeezed (Picture 5). Note, the nozzle lever can travel backwards past the safety interlock before fuel will flow, this was done to provide for one handed fuel operation.
Step 3: Either find a suitable piece of gasoline powered
equipment that needs gasoline or go to the host vehicles gas tank filler
neck to begin the flow adjusting procedure. Position 
the nozzle so that it is sufficiently inserted
and insert the short side of the Allen wrench into the flow adjuster, release
the safety and begin fueling while slowly turning the flow adjuster counter
clockwise. As you proceed the flow will increase, continue to increase the
flow until the engine's idle starts to become unstable or rough. Should
the engine stall, turn the flow adjuster in 1/2 turn from where your left
off and restart the engine and begin again. Once the engines idle begins
to become rough, slowly turn the flow adjuster in (clockwise) 1/8 turn at
a time until the engines idle stabilizes, then in 1/8 turn further. Release
the fuel nozzle lever and start filling and stopping a couple of times to
check for proper flow adjustment. If the engine idles rough or stalls while
fueling turn the adjuster in slightly (1/8 turn) and try again.
Step 4: Once the flow rate has been maximized re-install the flow adjuster dust cover. When fueling is finished, shut off the engine and disconnect the quick connect fuel and vapor recovery couplers. To disconnect the vapor hose push the outer collar of the vapor quick connect (auto side) forward or away from you and the lines will pop open. To disconnect the fuel supply hose retract the collar towards you and pull the connector straight back gently, this may take a few practices to feel natural. Always disconnect the vacuum side first. Always store your EZ-FUEL nozzle and hose assembly including safety glasses in its protective carrying case.
Maintenance
To insure trouble-free service
lubricate the fuel and vacuum couplers with WD-40 or CRC at least
twice per year and keep the dispensing hose assembly in its
protective case when not in use.
Trouble Shooting
EZ-FUEL does not effect the
integrity of vehicle's fuel system and vacuum systems but it may
reveal defects within these systems. Engine stalling and/or low fuel
flow rates when using EZ-FUEL may mean a clogged fuel filter, a
defective MAP sensor or a clogged or failing fuel pump. These types
of defects often go unnoticed under day-to-day driving conditions.
If found to be defective these items should be replaced in order to
ensure maximum performance from your vehicle and the EZ-FUEL
system.
