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DivisionX Return-Style Fuel System - X FactorLethal Performance's Grabber Blue Terminator is outfitted with a new fuel system From the October, 2012 issue of 5.0 Mustang & Super Fords By Steve Turner Photography by Steve Turner
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Since the day we met Lethal Performance's Jared Rosen, he's been talking about the Terminator that started him down the path to combining his business and pleasure. And in all that time, Jared's been busy driving his company to new levels while pushing the performance envelope with new Bosses, GTs, and GT500s. In the meantime, the Terminator just needed a few loose ends tied up to be back on the road. When Jared suggested that he might make a bold move with his '03 Cobra and do more than just make it road-worthy, we were in full support. When he suggested he'd paint it Grabber Blue, we turned a different shade--green with envy. It's been a while since Jared shared his plans. The car has had its drivetrain in and out, and it's been repainted in the aforementioned hue. Now it's time to supply it with enough fuel to support its upcoming move--the 4.0-liter supercharger. That brings us to these pages--just in time, Lethal's DivisionX line has a new '03-'04 Cobra 1,200-plus-rwhp return-style fuel system. Follow along as Power by the Hour installs the system in Jared's new Grabber Termi. Horse Sense: DivisionX doesn't stop at fuel hats for SN-95s and New Edges. The company also offers multi-pump, return-style fuel hats for all '05-'10 Mustangs and '07-'12 GT500s. They feature the same OEM connectors and plug-and-play goodness as the SN-95/New Edge hats detailed here.  Even way up on the two-post...  Even way up on the two-post lift, Jared Rosen's Grabber Blue Terminator is striking. Once it's all together, we'll take more photos of it, but for now we have to say Jared made the right might move with the color change.  Here's Lethal's complete '03-'04...  Here's Lethal's complete '03-'04 Cobra 1,200-plus-rwhp Return-Style Fuel System. The system goes for $1,799.95. It includes a DivisionX dual Walbro DCSS fuel hat, DivisionX fuelrails, two Walbro 400-lph DCSS fuel pumps, an Aeromotive 10-micron fuel filter, an Aeromotive four-port Pro Series EFI fuel pressure regulator, a Lethal Performance dual return-style wiring harness, Fragola Push-Lite fuel hose, Fragola XRP fittings, and all the necessary installation hardware.  The DivisionX dual-pump fuel...  The DivisionX dual-pump fuel hat is designed to accept Walbro GSS 342, DCSS 400s, and DX340 pumps, as well as the Stryker pump and Aeromotive 340 Stealth pumps. Knowing he was looking for huge power with this Terminator, Jared opted for a pair of the Walbro 400-lph DCSS fuel pumps. With a steady supply of 13.5 volts, these pumps will deliver the rated 400 liter per hour at 40 psi. With two of them in the DivisionX hat, you can feed 1,200 horses. After installing the pump sock, Jared slides the pumps into the hat.  As you install the DCSS pumps,...  As you install the DCSS pumps, make sure they are installed at the proper depth. Too high or too low and you could starve the pumps. Fortunately it's easy to measure the space between the mounting ring and the lower ring on the pump, where you want a 3/8-inch space. A short length of hose joins the pumps to the hat. As you are sliding the pumps into place be sure that the clamps are already on the hose. It requires some elbow grease to push them in, so you don't want to do it twice. With the pump's outlet port in the hose, you can tighten the clamps.  After wiring up the pumps...  After wiring up the pumps to the connector in the hat, Jared transfers the fuel-level sending unit from the stock fuel pump assembly to the DivisionX hat. This hat is designed to accept an '03-'04 Cobra sender. However, you can adapt a '99-'04 GT, '03-'04 Mach 1, or '99-'01 Cobra level sender with an optional adapter bracket.  Here Jared uses a bit of RTV...  Here Jared uses a bit of RTV to adhere the gasket to the hat so it doesn't slide out of alignment with the mounting holes.  With the pumps and level sensor...  With the pumps and level sensor installed, Jared shimmies the DivisionX fuel hat into the stock Terminator fuel tank. It takes a little patience to get the hat into place, but it's not too difficult.  The DivisionX hat installs...  The DivisionX hat installs in the stock tank using the stock mounting holes. However, it uses these new Allen-head fasteners.  After the hardware, it's time...  After the hardware, it's time to wire the new pumps. They require a steady supply of juice, so Jared feeds the main power wires from the back of the car to the power tap on the fuse box in the engine compartment.  Before plugging in the pumps...  Before plugging in the pumps and installing the tank, it's time to install the -8 feed and -6 return lines to the DivisionX hat. The Lethal system includes the necessary lengths of Fragola push-lock hose and the required Fragola XRP fittings. Just like their description implies, you just cut the hose to the needed length and push the fittings into the hose. That's it.  Here Jared feeds the power...  Here Jared feeds the power wires from the front of the car into the trunk. The plug-and-play harness included in the Lethal fuel system is also available on its own for $149. It includes these two 10-gauge power wires, two 40-amp waterproof relays with waterproof fuses, as well as an OEM-style six-pin connector.  You do need to tap into a...  You do need to tap into a few of the factory wires for this install, but after that it's all plug and play. Here Harvey of Power by the Hour protects these connections with heat-shrink tubing.  Harvey raises the freshly...  Harvey raises the freshly pumped-up tank into place. Be sure to slide the tank onto the filler neck before you strap it in.  Harvey Hecko mounted the relays...  Harvey Hecko mounted the relays and connectors from the Lethal harness on the existing fuel-pump-driver-module bracket.  With the wiring all sewn up,...  With the wiring all sewn up, it's just necessary to feed the connector through an existing hole in the trunk floor. The OEM connectors make these hats plug-and-play easy. This connector plugs right into the DivisionX hat; should you ever need to drop the tank, you can just unplug the pumps.  With the tank installed, Harvey...  With the tank installed, Harvey and Jared carefully routed the feed and return hose along the underside of the car using the clamps and screws included in the kit. Along the framerail, they spliced in the included Aeromotive fuel filter.  In the engine compartment...  In the engine compartment Jared installed the DivisionX Y-block to divert the fuel from the feed line to both of the DivisionX fuel rails.  Betwixt the feed line and...  Betwixt the feed line and the Y-block, Jared installs the included Aeromotive four-port fuel pressure regulator. The return line attaches to the regulator here also, so unneeded fuel is routed back to the tank. With the lines and a fuel-pressure gauge attached to the regulator, it’s mounted to the inner fender.  The Aeromotive regulator is...  The Aeromotive regulator is boost-referenced, so it increases fuel pressure by one psi for every pound of boost. This helps the fuel pressure keep pace with the pressure in the cylinders.  Jared had already set his...  Jared had already set his Terminator up with DivisionX fuel rails, but they are included in the full system. The rails are designed to clear all the popular aftermarket superchargers, and the driver-side rail accepts the stock fuel-pressure sensor. Jared will need that supercharger clearance, as he plans to move up from the 2.9-liter supercharger to a massive 4.0-liter.
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