2nd Gen Fuel Cell install retaining EVAP and stock pump write-up (including parts list)

*I will try to add more pictures later.

I didn't see a lot of consolidated info on adding a fuel cell, so I thought I'd share what I did to make it work. We don't have state inspections here, but I didn't want a CEL. That's why I wanted to keep the canister. I also kept the stock sender just to make things easier. There may be more affordable fittings and easier ways to do this, so please add to the conversation if you can.

Parts Used

1. RCI 2191A 19 Gallon Fuel Cell
2. Motobilt FUEL CELL MOUNT FOR 30 X 12 X 12 CELL
3. Motobilt TJ Fuel Pump clamping ring MB5007
4. Qty. (2)
   $12 EVIL ENERGY 8AN Flare Cap Block off Fitting Plug Black 2PCS
   EVIL ENERGY AN8 Flare Cap Tube Fitting Hex Head Port Fitting Adapter 2PCS Aluminum
   
5. I just used the hose and clamps from this Qty. (2)
   $14 IZOKEE 5/16" Inch ID Fuel Line Set - 2 Meter / 6-Foot 5/16" Inch Fuel Line + 2 Pcs 5/16" Fuel Filters + 10 Pcs 2/5" ID Hose Clamps for Kawasaki Kohler Briggs & Stratton Small Engine
   IZOKEE 5/16 " Inch ID Fuel Line Set - 2 Meter / 6-Foot 5/16" Inch Fuel Line + 2 Pcs 5/16 Inch Fuel Filters + 10 Pcs 2/5" ID Hose Clamps for Kawasaki Kohler Briggs & Stratton Small Engine
   
6. Qty. (2)
   $11 ICT Billet Quick Connect Male 5/16 Fuel Rail Hose to 5/16 Barb Adapter Fitting LS1 LM7 LR4 LQ4 LS6 L59 LQ9 LM4 L33 GM Oring Seal Billet Aluminum Natural Finish AN817-01-05BA
   ICT Billet Quick Connect Male 5/16 Fuel Rail Hose to 5/16 Barb Adapter Fitting LS1 LM7 LR4 LQ4 LS6 L59 LQ9 LM4 L33 GM Oring Seal Billet Aluminum Natural Finish AN817-01-05BA
7. Qty. (2)
   $14 Dorman 800-080 Fuel Line Quick Connector That Adapts 5/16 In. Steel To 5/16 In. Nylon Tubing, 2 Pack
   Dorman 800-080 Fuel Line Quick Connector That Adapts 5/16 In. Steel To 5/16 In. Nylon Tubing, 2 Pack These require the hardlines under the cab to be cut down about 1/8"
8. Qty. (1)
   $13 EVIL ENERGY 10AN Female to 10AN Female 90 Degree Swivel Coupler Union Fitting Adapter Aluminum Black
   EVIL ENERGY 10AN Female to 10AN Female 90 Degree Swivel Coupler Fitting Adapter Union Aluminium Anodized Black
   
9. Qty. (1)
   $10 ICT Billet -10AN Flare to 3/4" (.75) Hose Barb Adapter Fitting Aluminum Flare Connector Fluid Designed & Manufactured in the USA Bare Aluminum F10AN750BA-A
   ICT Billet -10AN Flare to 3/4" (.75) Hose Barb Adapter Fitting Aluminum Flare Connector Fluid Designed & Manufactured in the USA Bare Aluminum F10AN750BA-A
   
10. Qty. (1) Vibrant Performance Filter w/ Chrome Cap -3/4-19mm"Inlet ID 2164
    
11. 3/4" hose clamps

I went with an RCI 2191A 19 Gallon Cell, but I would highly recommend purchasing Motobilt's 19 gallon package deal. It will include the ring, cell and bracket that all works together. I already had the RCI before I knew this so I just went with it. I purchased a clamp ring and mounting brackets from Motobilt. I had to drill a hole for the stock sender in the RCI cell. The stock sender must be ground down a bit to fit in the ring. I used the round rubber ring from the stock pump as well to ensure a tight seal-



Fuel Lines
I had to trim about 1/8" off of the hardlines under the cab to get the quick disconnects (#7) to fully seat. Make sure to round off the edges and the plastic coating so the o-ring doesn't get punctured. This will allow the fuel lines to be easily extended to the pump. You can see in the picture above that the bundy connectors (#6) connect directly to the factory pump. From there it's just cut your hose and slide on the barb ends and clamp.

EVAP Lines
There's a lot of crap coming off the canister. Take good pictures and forget what goes to the OEM filler neck. I sealed of the two pickup and return lines on the cell with 8AN caps (#4). The rollover vent on the cell I used for connecting the 3/4" on the canister. I needed to adapt 8AN to 3/4" barb. There may be an easier cheaper solution, but I used parts #6, 8, 9, 11 to do this. I used a 3/4" filter (#10) on the end of the small box connected to the big canister. I will add better pictures of this later.

 

I like where this is going.

 

Aside from swapping the fuel lines under the cab because I had them backwards, it went without a hitch haha I had help from folks on here much smarter than I. Mostly @Tacoma1192 @Robertocritser @xweslingx and anyone else I left out/pestered to death

 

sub'd

 

Very nice work!

 

This turned out clean. Using the TJ mount from Motobuilt was clutch. I had some rings machined for when I install stock fuel pumps into fuel cells. $80 is a hell of a lot cheaper than what I paid.

 

In hindsight I should have just grabbed the whole package deal and I wouldn’t have to have cut the RCI or anything. Hell maybe a jeep pump could have worked. I also like that I was able to support another business here in Alabama. They’re awesome to work with and went above and beyond to get measurements and tech drawings to see if the taco pump would fit.

 

I'll probably be ordering from them for this 3rd gen I'm 4 linking. I was going to ditch the OEM this time and drop a holly intake pump in there but the new 3rd gen pumps are returnless. They have a bunch more shit in the fuel pump assembly for the pressure relief valves.

 

Interesting…
Why?

 

because there’s no more room under the truck for a fuel tank.

 

Now it all makes sense…
Pics are worth a 1000 words..
Good luck OP..

 

No more room for the stock tank after linky poos are in the way. That’s the only reason for me haha

 

Yea,,, plastic is not in your best interest

Nice

 

So I searched high and low for someone that's done a write up on this. Very good info, I'm doing a similar setup and ordered the fuel line fittings you linked. One issue, which I can only assume is specific to the prerunner? My 2006 prerunner uses two different size fuel lines, one is the 5/16 the other is 1/4. Odd that toyota ran different size lines on the prerunner vs the 4x4. Any which way, if anyone is doing this swap check your fuel line sizes, I used calipers on my metal lines where the plastic lines from the fuel tank connected to verify size. I then ordered the proper fittings and plastic line vs rubber hose, I already had the Dorman tool for pressing the quick connects into plastic lines. Thanks for the write up though, finding this thread helped me make the jump to a fuel cell.

 

Thanks man. It’s a good starting point for someone. I need to add some pictures to this thread. Didn’t know that about the prerunners. That’s good info.

 

Definitely a good starting point! I couldn't find crap on this, except for your thread. Which it's actually a pretty straight forward deal. I built my own tank, just for ease of running the stock pump/sending unit. I am tossing my evap stuff, I've battled with it for FAR to long. My trucks getting a LS swap (hopefully nest spring) at which point I'll buy a proper fuel cell. But for now it'll work out just fine, bonus my tank I built is a 26gal....

 

Do you remember how tall the fuel pump is? Trying to figure out where to start my set up.

 

I don’t remember honestly, but it just fits fully extended in the RCI cell I have. If I were to do it again I’d get the Motobilt kit for the jeeps as it will have everything you need and our pump will fit it with the same amount of trimming.

 

11 inches from flange to tank bottom on my stock tank.

 

Got the motobilt kit, really wanted a 30 ish gallon cell but it is damn near impossible to find something bladerless over 20 so the motobilt was the easiest option.