In the configuration of high-pressure systems, the inner diameter of the fuel pipeline must match the flow parameters of the pump body. When installing a Fuel Pump with a flow rate of ≥80L/h, the inner diameter of the supply pipe should not be less than 8mm (cross-sectional area ≥50.3mm²); otherwise, if the flow rate exceeds 4m/s, an additional pressure loss of more than 55kPa will be generated. A typical case is the Ford Mustang GT500 Track Edition. Its 76mm cylinder diameter fuel supply pipe keeps the fuel pressure stable at 7000rpm (fluctuation ≤±4%), and the peak power is increased by 11% compared with the 6mm pipe diameter scheme.
The thermal stability of pipeline materials is related to safe operation. The use of PTFE-lined stainless steel braided oil tubes (with a temperature resistance range of -40℃ to 230℃) can reduce the risk of burst to 0.3% compared with rubber tubes (with a maximum temperature resistance of 120℃). The measured data of the Porsche 919 Hybrid Hybrid racing car shows that when the surface temperature of the oil pipe in the engine compartment reaches 182℃, the volume expansion rate of the PTFE pipe is only 0.7%, while the SAE J30R9 rubber pipe will expand by 4.5%, resulting in an 18% decrease in flow rate.
The anti-cavitation layout needs to follow the principles of fluid dynamics. The minimum interval between the return oil pipeline and the supply oil pipeline should be greater than 25mm, and a 2% inclination slope should be set to ensure that the bubble venting efficiency is greater than 97%. In the retrofit case of the Camaro ZL1LE, the optimized oil circuit layout increased the NPSH (Net Positive Suction Head) value from 1.2m to 2.8m, and the cavitation noise decreased by 15dB(A). The key criteria include: avoiding sharp bends less than 120° (elbow curvature radius ≥3 times the pipe diameter), and adding pipe clamps every 300mm to reduce vibration displacement (amplitude ≤0.1mm).
Thermal management strategies directly affect the service life of the oil circuit. The fuel line in the engine compartment should be at least 80mm away from the exhaust manifold and be equipped with an aluminum foil heat insulation cover (with a surface temperature drop of 45℃). The BMW M4 GTS adopts a double-wall insulated oil pipe design, which stabilizes the pipe wall temperature at 65±5℃ (ambient temperature 142℃), reducing heat penetration by 83% compared to single-layer pipes. According to the SAE J2044 standard, continuous contact temperature > 110℃ will lead to the shortening of the oil pipe life to 30% of the original value.
The standardized implementation can bring significant economic benefits. The pipeline layout in compliance with the ISO 4038 standard extends the maintenance cycle to 5 years / 100,000 kilometers and reduces the single installation cost by 35%. The practice of the Audi R8 LMS team shows that after optimizing the fuel line, the failure rate of the fuel system has dropped to 0.4 times per 10,000 kilometers, and the maintenance budget has been saved by 18,000 euros per season. Diagnostic data show that the correct use of the AN-8 specification joint (with a tightening torque of 28N·m) can control the leakage probability within 0.01%.
