2.0 LSJ Engine: Return-style fuel system for 2.0 LSJ
Parts needed
1. Walbro GSS342 - longer than stock fuel pump
2. Aeromotive A1000-6 Part# 13109 regulates from 30-70psi
3. Fuel lines (20 -25ft)
4. fittings
5. fuel filter (1 input, 1 output)
6. Aeromotive one-way check valve or Earl Performance check valve
7. 2 Straight hose-end 6AN fitting
8. male adapter connector to female end on check-valve
Step 1
Take out the tank. Several bolts need to be unscrewed. Try to have an almost empty tank. It'll weight less.
Step 2
Take out the module inside the tank. Be careful to take out the cap where the fuel pump is located. It has like 4 clips. Use a philips screw driver.
Step 3
Take the stock fuel pump out. Take out the in-tank regulator.
Step 4
Insert Walbro GSS342. Warning, this fuel pump does not fit in the location where to stock pump is located. Put back the cap and tied firmly with 3 straps.
Step 5
Replace one of the fuel lines that goes into the tank with a fuel line. This one goes from the tank to the bottom of the regulator. You gotta be extremely careful here, try not to break the plastic fuel input of the module inside the tank.
This is the replaced line:
These are the fuel lines i used:
Step 6
Installed regulator.
Step 7
Here you got two choices. Either buy a 2002 Ecotec fuel rail, which is already tapped, or tapped the stock fuel rail, that's what I did. Connect a fuel line from the side of the regulator to where the fuel rail is tapped. You'll know where to tapped because the fuel rail the LSJ uses is the same as the cavalier except the LSJ's is blocked. Drill and connect fitting.
Step 8 Verify for leaks and connect vacuum hose. You have to get a T, cut one of the vacuum lines and install. Replace the fuel filter. It needs a 1 input, 1 output type and be aware of the flow directions.
Step 9 Test for leaks. Switch to Run until the pump fills the fuel line. You'll here a small whine and when the fuel pump stops. Remember, you have to do this everytime you start the car. The regulator does not hold fuels in the lines like the intank regulator.
Step 10 Use a wideband to setup the fuel pressure. Set the pressure. Try to set it for 40-41 psi. At vacuum should be 50-51psi.
After the installation, I went to a dyno and set AFR to 10.8. Dyno results after return style and fujita CAI. The KR I got before the return-style, gone.
1. Walbro GSS342 - longer than stock fuel pump
2. Aeromotive A1000-6 Part# 13109 regulates from 30-70psi
3. Fuel lines (20 -25ft)
4. fittings
5. fuel filter (1 input, 1 output)
6. Aeromotive one-way check valve or Earl Performance check valve
7. 2 Straight hose-end 6AN fitting
8. male adapter connector to female end on check-valve
Step 1
Take out the tank. Several bolts need to be unscrewed. Try to have an almost empty tank. It'll weight less.
Step 2
Take out the module inside the tank. Be careful to take out the cap where the fuel pump is located. It has like 4 clips. Use a philips screw driver.
Step 3
Take the stock fuel pump out. Take out the in-tank regulator.
Step 4
Insert Walbro GSS342. Warning, this fuel pump does not fit in the location where to stock pump is located. Put back the cap and tied firmly with 3 straps.
Step 5
Replace one of the fuel lines that goes into the tank with a fuel line. This one goes from the tank to the bottom of the regulator. You gotta be extremely careful here, try not to break the plastic fuel input of the module inside the tank.
This is the replaced line:
These are the fuel lines i used:
Step 6
Installed regulator.
Step 7
Here you got two choices. Either buy a 2002 Ecotec fuel rail, which is already tapped, or tapped the stock fuel rail, that's what I did. Connect a fuel line from the side of the regulator to where the fuel rail is tapped. You'll know where to tapped because the fuel rail the LSJ uses is the same as the cavalier except the LSJ's is blocked. Drill and connect fitting.
Step 8 Verify for leaks and connect vacuum hose. You have to get a T, cut one of the vacuum lines and install. Replace the fuel filter. It needs a 1 input, 1 output type and be aware of the flow directions.
Step 9 Test for leaks. Switch to Run until the pump fills the fuel line. You'll here a small whine and when the fuel pump stops. Remember, you have to do this everytime you start the car. The regulator does not hold fuels in the lines like the intank regulator.
Step 10 Use a wideband to setup the fuel pressure. Set the pressure. Try to set it for 40-41 psi. At vacuum should be 50-51psi.
After the installation, I went to a dyno and set AFR to 10.8. Dyno results after return style and fujita CAI. The KR I got before the return-style, gone.
Senior Member
Joined: 09-05-07
Posts: 10,662
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From: Sasebo Japan
how about gas mileage..or a raising pressure of fuel with ur boost so u dont gotta run injectors that are for 800hp cars...those are just 2...luckily my honda comes stock with a return style
Senior Member
Joined: 06-28-06
Posts: 12,577
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From: Canada
Id love to see some documentation, or information showing how it is beneficial
Senior Member
Joined: 05-02-07
Posts: 1,061
Likes: 0
From: San Jose, CA
Senior Member
Joined: 06-28-06
Posts: 12,577
Likes: 2
From: Canada
see, (dont take this the wrong way) but thats all ive heard so far about returnless....opinions
I just want to know exactly why it is beneficial for a 250-350hp cobalt.
again, im not saying its junk and pointless,
im just saying id love to see some hard proof, some convincing articles....just something concrete to
convince me that this might be worth me investing in.
I just want to know exactly why it is beneficial for a 250-350hp cobalt.
again, im not saying its junk and pointless,
im just saying id love to see some hard proof, some convincing articles....just something concrete to
convince me that this might be worth me investing in.
Senior Member
Joined: 09-17-05
Posts: 5,844
Likes: 0
From: Pittsburgh, PA
see, (dont take this the wrong way) but thats all ive heard so far about returnless....opinions
I just want to know exactly why it is beneficial for a 250-350hp cobalt.
again, im not saying its junk and pointless,
im just saying id love to see some hard proof, some convincing articles....just something concrete to
convince me that this might be worth me investing in.
I just want to know exactly why it is beneficial for a 250-350hp cobalt.
again, im not saying its junk and pointless,
im just saying id love to see some hard proof, some convincing articles....just something concrete to
convince me that this might be worth me investing in.
Senior Member
Joined: 06-28-06
Posts: 12,577
Likes: 2
From: Canada
genius.
thanks for the positive input.
do you have anything to backup your smartass comment?
or are you gonna ride everyones coat tails, and pretend you know the answers?
if so, like i said, id love to hear them, im here to learn.
if not? go **** yourself.
k i can understand the 60s not doin the job....
but why returnless, instead of a larger injector?
is it not possible to run larger without returnless?
does returnless allow far greater performance out of 60s?
thanks for the positive input.
do you have anything to backup your smartass comment?
or are you gonna ride everyones coat tails, and pretend you know the answers?
if so, like i said, id love to hear them, im here to learn.
if not? go **** yourself.
but why returnless, instead of a larger injector?
is it not possible to run larger without returnless?
does returnless allow far greater performance out of 60s?
Last edited by an0malous; Jul 6, 2008 at 01:51 AM. Reason: Automerged Doublepost
Senior Member
Joined: 09-05-07
Posts: 10,662
Likes: 0
From: Sasebo Japan
most hondas come stock to return style..no need to switch
i just dont understand running an injector that is for a 900hp car (79lbers) and spending 300-500 bucks on them when u can run 42's on a return style and be fine when my return style only cost me 300 bucks..and tuning them is so much easier
genius.
thanks for the positive input.
do you have anything to backup your smartass comment?
or are you gonna ride everyones coat tails, and pretend you know the answers?
if so, like i said, id love to hear them, im here to learn.
if not? go **** yourself.
k i can understand the 60s not doin the job....
but why returnless, instead of a larger injector?
is it not possible to run larger without returnless?
does returnless allow far greater performance out of 60s?
thanks for the positive input.
do you have anything to backup your smartass comment?
or are you gonna ride everyones coat tails, and pretend you know the answers?
if so, like i said, id love to hear them, im here to learn.
if not? go **** yourself.
k i can understand the 60s not doin the job....
but why returnless, instead of a larger injector?
is it not possible to run larger without returnless?
does returnless allow far greater performance out of 60s?
i just dont understand running an injector that is for a 900hp car (79lbers) and spending 300-500 bucks on them when u can run 42's on a return style and be fine when my return style only cost me 300 bucks..and tuning them is so much easier
Last edited by Raven SS; Jul 6, 2008 at 01:53 AM. Reason: Automerged Doublepost
genius.
thanks for the positive input.
do you have anything to backup your smartass comment?
or are you gonna ride everyones coat tails, and pretend you know the answers?
if so, like i said, id love to hear them, im here to learn.
if not? go **** yourself.
k i can understand the 60s not doin the job....
but why returnless, instead of a larger injector?
is it not possible to run larger without returnless?
does returnless allow far greater performance out of 60s?
thanks for the positive input.
do you have anything to backup your smartass comment?
or are you gonna ride everyones coat tails, and pretend you know the answers?
if so, like i said, id love to hear them, im here to learn.
if not? go **** yourself.
k i can understand the 60s not doin the job....
but why returnless, instead of a larger injector?
is it not possible to run larger without returnless?
does returnless allow far greater performance out of 60s?
a return style does allow for better performance out of the 60's no doubt. My idc's went from 130% at 6200 rpms running a 12.4 afr to 83% at 7200 with a 12.0 afr.
Senior Member
Joined: 06-28-06
Posts: 12,577
Likes: 2
From: Canada
most hondas come stock to return style..no need to switch
i just dont understand running an injector that is for a 900hp car (79lbers) and spending 300-500 bucks on them when u can run 42's on a return style and be fine when my return style only cost me 300 bucks..and tuning them is so much easier
i just dont understand running an injector that is for a 900hp car (79lbers) and spending 300-500 bucks on them when u can run 42's on a return style and be fine when my return style only cost me 300 bucks..and tuning them is so much easier
question though....is the efficiency increased because of return?
or is it because of the higher pressure walbro pump?
as ive seen the pump thing is a pretty popular upgrade for the srt4 guys
any negative effects on the injector to run it this way?
Last edited by an0malous; Jul 6, 2008 at 02:57 AM. Reason: Automerged Doublepost
Senior Member
Joined: 05-02-07
Posts: 1,061
Likes: 0
From: San Jose, CA
I started with stage 2 and 42s. I decided to run a smaller pulley and found that I run out of injector up top. I install 60s. This is all familiar, and what everyone does, right? Well, here is the problem with that. The first problem is that our PCM limits the IFR table so that we have to make up for it with either using a modifier (far from impecable) or by other means that are even less ideal. We also know that as we increase injector size, we lose the ability to flow them accurately at the low PWs our cars require. This makes them not want to behave during idle and light cruise. The bigger the injector, the worse the low PW performance - unless, of course you are going with disc injectors, but then you still have to deal with the whole 63.5 thing.
I switch to a return style system and here is what I get out of it: First of all, I set my base pressure so that my IFR is at exactly 63.5 across the board. I now KNOW 100% that my IFR table is correct. Also, before, when my pressure was a semi static 58psi, my 60s idled at about .980-1.000ms and light cruise had me at .875-.950ms, which is well under the linear range with those injectors. Now I idle at about 1.2-1.3ms which the injectors like fine. My idle is butter smooth at 850 rpms at all times. Also, dead head returnless systems get "creap". This is when you are supplying 58psi to a dead head rail for a length of time and the rpessure will begin to grow higher and higher untill you open up the injectors and dump a quantity of fuel to releave some pressure. This cannot happen with a pass through system.
There are also benefits that I believe I have gained, but they are speculative, so I will leave them out of this discussion. I will say that i do not spend my money lightly, nor my time, but for me, the accuracy of the tuning alone is well worth this mod. Never mind that the car "feels" way better.
Senior Member
Joined: 06-28-06
Posts: 12,577
Likes: 2
From: Canada
appreciate you takin the time to write that up.
thats exactly the kind of real world experiences i was lookin for
Like yourself, I dont spend my money lightly either,
just doing my due diligence on a possible purchase
thats exactly the kind of real world experiences i was lookin for
Like yourself, I dont spend my money lightly either,
just doing my due diligence on a possible purchase
Senior Member
Joined: 05-02-07
Posts: 1,061
Likes: 0
From: San Jose, CA
Last edited by SJSchafer; Jul 6, 2008 at 03:19 AM. Reason: Automerged Doublepost
Senior Member
Joined: 09-17-05
Posts: 5,844
Likes: 0
From: Pittsburgh, PA
genius.
thanks for the positive input.
do you have anything to backup your smartass comment?
or are you gonna ride everyones coat tails, and pretend you know the answers?
if so, like i said, id love to hear them, im here to learn.
if not? go **** yourself.
k i can understand the 60s not doin the job....
but why returnless, instead of a larger injector?
is it not possible to run larger without returnless?
does returnless allow far greater performance out of 60s?
thanks for the positive input.
do you have anything to backup your smartass comment?
or are you gonna ride everyones coat tails, and pretend you know the answers?
if so, like i said, id love to hear them, im here to learn.
if not? go **** yourself.
k i can understand the 60s not doin the job....
but why returnless, instead of a larger injector?
is it not possible to run larger without returnless?
does returnless allow far greater performance out of 60s?
Senior Member
Joined: 06-28-06
Posts: 12,577
Likes: 2
From: Canada
Im sorry you dont like me frazier, but frankly, i dont give a ****.
i notice you waited till everyone else gave information before you replied.
and your reply contains no information at all.
gee what a shock.
so for someone accusing me of being a know it all,
you sure prooved that you dont know **** either, and just wanted to take a shot at me.
At least im not to proud to know that I DONT know it all, and was quite willing to ask for help.
that doesnt sound like the actions of someone who pretends to "know it all" now does it?
or is this maybe your sour grapes over the last thread you attacked me in?
i notice you waited till everyone else gave information before you replied.
and your reply contains no information at all.
gee what a shock.
so for someone accusing me of being a know it all,
you sure prooved that you dont know **** either, and just wanted to take a shot at me.
At least im not to proud to know that I DONT know it all, and was quite willing to ask for help.
that doesnt sound like the actions of someone who pretends to "know it all" now does it?
or is this maybe your sour grapes over the last thread you attacked me in?
Senior Member
Joined: 09-17-05
Posts: 5,844
Likes: 0
From: Pittsburgh, PA
Im sorry you dont like me frazier, but frankly, i dont give a ****.
i notice you waited till everyone else gave information before you replied.
and your reply contains no information at all.
gee what a shock.
so for someone accusing me of being a know it all,
you sure prooved that you dont know **** either, and just wanted to take a shot at me.
At least im not to proud to know that I DONT know it all, and was quite willing to ask for help.
that doesnt sound like the actions of someone who pretends to "know it all" now does it?
or is this maybe your sour grapes over the last thread you attacked me in?
i notice you waited till everyone else gave information before you replied.
and your reply contains no information at all.
gee what a shock.
so for someone accusing me of being a know it all,
you sure prooved that you dont know **** either, and just wanted to take a shot at me.
At least im not to proud to know that I DONT know it all, and was quite willing to ask for help.
that doesnt sound like the actions of someone who pretends to "know it all" now does it?
or is this maybe your sour grapes over the last thread you attacked me in?
Senior Member
Joined: 06-28-06
Posts: 12,577
Likes: 2
From: Canada
awww is that the best you can do?
QQ and little quips because you dont have the intelligence to truely come up with a reply?
lol.
your a waste of perfectly good bandwidth.
lets get back to the intelligent conversation with all the other people in this thread who have a clue shall we?
maybe youll learn something too.
QQ and little quips because you dont have the intelligence to truely come up with a reply?
lol.
your a waste of perfectly good bandwidth.
lets get back to the intelligent conversation with all the other people in this thread who have a clue shall we?
maybe youll learn something too.
Senior Member
Joined: 09-17-05
Posts: 5,844
Likes: 0
From: Pittsburgh, PA
awww is that the best you can do?
QQ and little quips because you dont have the intelligence to truely come up with a reply?
lol.
your a waste of perfectly good bandwidth.
lets get back to the intelligent conversation with all the other people in this thread who have a clue shall we?
maybe youll learn something too.
QQ and little quips because you dont have the intelligence to truely come up with a reply?
lol.
your a waste of perfectly good bandwidth.
lets get back to the intelligent conversation with all the other people in this thread who have a clue shall we?
maybe youll learn something too.
