Apparatus and method for modifying a fuel tank to accept an in-tank fuel pump

1. A method of mounting a fuel pump in a fuel tank having an original fuel sending unit removably secured within a sending unit opening formed in the tank, the original fuel sending unit comprising a cap removably securable across the sending unit opening formed in the tank and having at least an original supply line conduit extending therethrough and an original fuel level sensor assembly connected to the cap and extending into the fuel tank when the cap is secured across the sending unit opening, the original fuel level sensor assembly electrically connected to a first sensor terminal extending through the cap, the method comprising the steps of:

removing the original fuel sending unit from the sending unit opening in the fuel tank;

providing a replacement cap for securement in covering relationship with the sending unit opening of the fuel tank, the replacement cap including a supply line conduit and a return line conduit extending therethrough and first and second terminals extending therethrough;

forming an access hole in the fuel tank;

connecting the fuel pump to a cover plate sized to cover the access opening with the fuel pump and cover plate forming a fuel pump module;

connecting a fuel supply line between an outlet of the fuel pump and an in-tank end of the supply line conduit of the replacement cap;

connecting an intake end of a fuel return line to an in-tank end of the return line conduit and positioning a discharge end of the fuel return line in the fuel tank;

connecting a power supply conductor between the in-tank fuel pump and the first terminal extending through the replacement cap;

connecting a ground conductor between the in-take fuel pump and the second terminal extending through the replacement cap;

inserting the fuel pump module into the tank through the access hole and securing the cover plate to the tank in covering relationship across the access hole with the fuel pump suspended in the fuel tank from the cover plate; and

securing the replacement cap to the fuel tank in covering relationship across the sending unit opening.

2. The method as in claim 1 wherein the step of providing the replacement cap for securement in covering relationship with the sending unit opening of the fuel tank includes providing the replacement cap having a third terminal extending therethrough, and the method further comprises: inserting a fuel level sensor assembly into the fuel tank through the access hole and mounting the fuel level sensor assembly in the fuel tank; and connecting a fuel level sensor signal conductor between the fuel level sensor and the third terminal extending through the replacement cap.

3. The method as in claim 2 further comprising providing a mounting ring sized for insertion into the tank through the access hole and positioning the mounting ring against the tank around the access hole and bolting the cover plate to the mounting ring to secure the cover plate to the tank and wherein the step of mounting the fuel level sensor assembly in the fuel tank comprises mounting the fuel level sensor assembly on a bracket connected to the mounting ring and the fuel level sensor assembly and bracket are inserted into the fuel tank upon insertion of the mounting ring therein.

4. The method as in claim 1 wherein prior to inserting the fuel pump into the fuel tank the method further comprises the step of inserting into or forming in the fuel tank a baffle positioned to surround an intake to the fuel pump when inserted into the fuel tank.

5. The method as in claim 4 wherein at least one check valve is positioned in an opening through the baffle to allow fuel to flow therethrough into but not out of the baffle.

6. The method as in claim 4 further comprising connecting a siphoning adapter to receive a stream of pressurized fuel from the fuel pump to create suction in a siphoning tube connected at a first end to the siphoning adapter and the method further comprises connecting a second end of the siphon tube in the tank remote from the baffle such that pumping of fuel through the siphoning adapter draws fuel from the tank through the siphon tube and the siphoning adaptor and discharges the siphoned fuel inside of the baffle.

7. A method of mounting a fuel pump in a fuel tank having a top wall and an original fuel sending unit removably secured within a sending unit opening formed in the fuel tank, the original fuel sending unit comprising a cap removably securable across the sending unit opening formed in the tank and having a single conduit comprising an original supply line conduit extending therethrough and an original fuel level sensor assembly connected to the cap and extending into the fuel tank when the cap is secured across the sending unit opening, the original fuel level sensor assembly electrically connected to a sensor terminal extending through the cap the method comprising the steps of:

a) removing the original fuel sending unit from the sending unit opening in the fuel tank;

b) providing a replacement cap for securement in covering relationship with the sending unit opening of the fuel tank, the replacement cap including a supply line conduit and a return line conduit extending therethrough and first, second and third terminals extending therethrough;

c) forming an access hole in the top wall of the fuel tank;

d) connecting the fuel pump to a cover plate sized to cover the access opening;

e) positioning the cover plate and fuel pump outside of the fuel tank and proximate the access hole therein;

f) connecting a first end of a fuel supply line to an outlet of the fuel pump;

g) threading a second end of the fuel supply line through the access hole, into the tank and out the sending unit opening;

h) connecting the second end of the fuel supply line to an in-tank end of the supply line conduit on the replacement cap;

i) inserting a fuel return line into the fuel tank through the access hole, positioning a first end of the fuel return line in the fuel tank in close proximity to a position in the fuel tank at which the fuel pump is to be mounted; and threading a second end of the fuel return line out the sending unit opening;

j) connecting the second end of the fuel return line to an in-tank end of the return line conduit on the replacement cap;

k) connecting a power supply conductor between the fuel pump and the first terminal extending through the replacement cap;

l) connecting a ground conductor between the fuel pump and the second terminal extending through the replacement cap;

m) connecting a fuel level sensor assembly to a cover plate mounting member;

n) inserting the cover plate mounting member and the fuel level sensor assembly into the fuel tank through the access hole;

o) connecting a fuel level sensor signal conductor between the fuel level sensor and the third terminal extending through the replacement cap;

p) inserting the in-tank fuel pump into the tank through the access hole and securing the cover plate to the cover plate mounting member in the tank with the cover plate extending in covering relationship across the access hole; and

q) securing the cap to the fuel tank in covering relationship across the sending unit opening.

8. The method as in claim 7 wherein the step of providing a cover plate mounting member comprises providing a mounting ring sized for insertion into the tank through the access hole and positioning the mounting ring against the tank around the access hole and bolting the cover plate to the mounting ring to secure the cover plate to the tank and wherein the step of connecting the fuel level sensor assembly to the cover plate mounting member comprises mounting the fuel level sensor assembly on a bracket connected to the mounting ring and the fuel level sensor assembly and bracket are inserted into the fuel tank upon insertion of the mounting ring therein.

9. The method as in claim 7 wherein prior to inserting the fuel pump into the fuel tank the method further comprises the step of inserting into or forming in the fuel tank a baffle positioned to surround an intake to the fuel pump when inserted into the fuel tank.

10. The method as in claim 9 wherein at least one check valve is positioned in an opening through the baffle to allow fuel to flow therethrough into but not out of the baffle.

11. The method as in claim 10 further comprising connecting a siphoning adapter to receive a stream of pressurized fuel from the fuel pump to create suction in a siphoning tube connected at a first end to the siphoning adapter and the method further comprises connecting a second end of the siphon tube in the tank remote from the baffle such that pumping of fuel through the siphoning adapter draws fuel from the tank through the siphon tube and the siphoning adaptor and discharges the siphoned fuel inside of the baffle.

12. A fuel tank adaptor assembly for use in mounting a fuel-pump in a fuel tank having a sending unit opening sized to receive an original fuel sending unit, the fuel tank adaptor assembly comprising:

a fuel pump including a fuel outlet, the fuel pump suspended from a cover plate;

a replacement cap for securement in the sending unit opening of the fuel tank, the replacement cap including a cap body having a supply line conduit and a return line conduit extending therethrough and first second, and third terminals extending therethrough;

a mounting ring sized for insertion into the fuel tank through an access hole formed therein with the mounting ring positionable against the tank around the access hole for bolting the cover plate to the mounting ring to secure the cover plate to the tank with the fuel pump suspended in the tank from the cover plate;

a fuel level sensor and a mount for mounting the fuel level sensor to the mounting ring in the fuel tank, the fuel level sensor having a fuel level signal conductor connected to and extending from the fuel level sensor and having a connector for operably connecting the fuel level signal conductor to the first terminal;

a power supply conductor connected to the power supply terminal of the fuel pump and having a connector for operably connecting the power supply conductor to the second terminal;

a pump ground conductor connected to the fuel pump and the pump ground conductor includes a connector for operably connecting the pump ground conductor to the third electrical terminal in the replacement cap;

a flexible, fuel supply line connected at an intake end to the fuel outlet of the fuel pump and having a discharge end operably connectable to the supply line conduit of the replacement cap; and

a flexible, fuel return line operably connectable at an inlet end to the return line conduit of the replacement cap and a return line connector for securing a discharge end of the flexible fuel return line within the fuel tank.

13. The fuel tank adaptor assembly as in claim 12 further comprising a baffle positioned to surround an intake to the fuel pump suspended in the fuel tank from the cover plate.

14. The fuel tank adaptor assembly as in claim 13 wherein at least one check valve is positioned in an opening through the baffle to allow fuel to flow therethrough into but not out of the baffle.

15. The fuel tank adaptor assembly as in claim 13 further comprising a siphoning adapter connected to receive a stream of pressurized fuel from the fuel pump and having a discharge positioned to discharge fuel into the baffle, the assembly further comprising a siphon tube having a first end connected to the siphoning adapter and a second end positionable in the tank remote from the baffle wherein the stream of pressurized fuel from the fuel pump flowing through the siphoning adapter creates suction in the siphoning tube and draws fuel from the tank through the siphon tube and the siphoning adaptor and discharges the siphoned fuel inside of the baffle.

16. The fuel tank adaptor assembly as in claim 13 further comprising a venturi type siphoning adaptor having a pressurized fuel inlet connected in-line with a branch from the fuel supply line, a discharge positioned to discharge fuel into the baffle and a siphon inlet, a siphon tube is connected at a first end to the siphon inlet of the siphoning adaptor and a second end of the siphon tube is adapted to be mounted in the fuel tank outside of the baffle.