Broken Fuel Cell retrofit project

[evantful]

Hi all, Im in the process of working a project to detail the required parts and steps needed to convert the fuel system from the older TBI 5.0/5.7Gi engines that used separated Low and High pressure pumps to the new style combined Fuel Cell that Volvo has been using since about 2000 to current.

The older system, specifically the VST tank and High Pressure system in the back of the engine has long since been made obsolete by Volvo Penta, with parts and service kits no longer being produced.

Most of it is just researching cross over parts and validating everything works. Ultimately I will write up a How-To with a detailed listing of part numbers to help other members make the switch down the road.

 

[evantful]

Actually, if anyone wants to do me a favor, you could take pictures of the numbers stamped on the Low and High Pressure pumps on the Fuel Cell that would work just fine too.

 

[alldodge]

I like the idea and look forward to your results.

Airtex makes low and high pressure pumps for marine and automotive suppliers. The VP pumps are the same as many other pumps. One is low pressure (under 12 psi) and the other is high pressure (60 psi). The regulator is the item which keeps the final output within specified parameters.

Airtex part numbers are:
Electric fuel low pressure E11003
Electric fuel high pressure E11004

 

[Powerstroke in a Prius]

Remember that the fuel cell uses raw water for cooling, so the plumbing thing gets interesting. I found the connector you need to adapt to the two pumps to your engine wiring harness. The engine side is an EV1LP-F1 Female Connector [LINK]

 

[dmitchr]

I recently bought a 1996 Pursuit Denali with a 5.7 Volvo Penta GSI. It had been sitting up for quite awhile and the ethanol in the fuel destroyed the fuel reservoir and high pressure pump. Since the fuel reservoir is no longer available, I have no choice but attempt to do exactly what you are doing, replacing my old low/high/ reservoir system with the newer one piece design found on the 1999-2000 model 5.7 GSI. That part number is 3861355. Any luck with the project?

Has anyone tried to completely replace the factory fuel pump system? I thinking about taking off both pumps and replace them with an in line aftermarket fuel pump mounted right at the fuel tank, then run the return line back to the fuel tank. I put a TBI chevy 350 in a 1979 Jeep CJ7 and run the fuel system exactly that way. It's been running like this for years with no issues. As long as the throttle body sees the proper fuel pressure, it does not care how it got there.