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Project Cappuccino: Upgrading the Fuel System

  • Dave Zipf
New fuel lines cut to length
We used the old lines as templates and cut our new Evil Energy fuel line to length. We then installed the new lines into the car and started the car to check for leaks. After spending 15 seconds purging air, the Capp settled into a happy idle with no leaks anywhere. We then reinstalled the interior to complete our fuel system maintenance.

Did this fix our problems?  No!  We actually found our issues while we were waiting for parts to arrive.  We went ahead and fixed our fuel system anyway since we had already ordered everything and wanted the insurance.

Blown boost hose with a split down most of its length
Our lack of power was down to this hose splitting right down the middle.
Cappuccino engine bay showing where the blown hose was located
The Cappuccino has a little bypass line just before the BOV. I am not 100% sure what this hose does (I think it helps pre-charge the intake system with a small amount of boost as the turbo pressurizes the intake system but there are so many damn vacuum lines in this car it’s hard to know for sure). We replaced this 4” piece of hose and it was like driving a completely different car. I suspect this hose initially failed during our dyno day and had been getting worse ever since. With the tear on the bottom of the hose it wasn’t visible until we discovered it working on the PCV system. I have a feeling we’re making more than the 69 hp at the wheels we saw on the dyno but we haven’t had a chance to get the Capp strapped down again.

Sources

Advanced Engine Management

Evil Energy

More Cappuccino

Coast to Coast in 5 Days Part 1

Coast to Coast in 5 Days Part 2

Witchcraft & Wizardry

Blitz DTT and Wrapping Up The Interior

Better Braking With Project Mu 

Modern Tires, Ancient Car

A Terrifying Problem

Clutches, Oil Leaks, and Kei Car Oddities

A Wee Bit O’ Power

Testing the Kei Sport USA PNP ECU

DIY Lithium Battery Installation

Driveline Love

Upgrading the Suspension

Nuts & Bolts are Wheely Cool

Installing an AOS

Related

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Related Topics
  • Project Cappuccino
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  • Cappuccino
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3 comments
  1. James says:
    July 16, 2025 at 10:58 am

    This is a cool project. Getting all the power back is a huge deal at such low numbers lol. I have really considered picking up an AZ-1. Didn’t you make a comparison article where you decided between the Cappucino, AZ-1, and the Beat?

    Reply
    1. Dave Zipf says:
      July 21, 2025 at 5:48 am

      Hey James,

      We have not done a full comparison of the ABC cars. I’ve test driven a couple of Beats and ridden in an AZ-1. In our Project intro for the Cappuccino I discussed my reasoning for picking a Cappuccino over a Beat or AZ-1. I think I would quickly summarize them thusly:

      AZ-1: Most expensive of the 3 due to its rarity (about double the price of a Cappuccino). Very cramped. No trunk or frunk. But man are they cool. It really is a mini DeLorean: awesome to look at and you’ll get a ton of questions but not the best day to day car. Also the cabin is a glass bubble so they get very hot in the summer.

      Beat: Usually the cheapest of the three. Super fun to drive, and they’re great with the top down. But slow as hell. Naturally aspirated 660cc engine just has no torque. Great engines once they’re wound up a bit. Great cruiser especially if you live somewhere you can have the roof down all the time. Great interior too. IIRC, the roomiest of the 3. The trunk is pretty small but the interior has lots of storage. Beware of leaky roofs. I’ve heard they’re not too hard or expensive to replace though.

      Cappuccino: Probably the best all rounder. Has a real trunk. Has a decent interior. 3-piece roof is great. Definitely the best for performance and the fastest of the 3 (that’s not saying much though). Lots of aftermarket support even today. I’ve had mine for 7 years now and still love it.

      For any of them there are a few things to keep in mind. Not sure where you’re from, but if you’re in the US, you will need to either be a good DIY mechanic, or line up a shop that is willing to work on your car. A lot of shops won’t work on them. The Cappuccino has an English service manual, not sure if the AZ-1 or Beat do. Make sure you inspect your car thoroughly. DIY maintenance on all of these cars is tough. Everything is small and cramped so you have to get creative working on them. All of these cars have a tendency to rust and sometimes it is not obvious. The cheapest route is the DIY import route but it’s the riskiest. Rust will be hard to spot in the port photos and you won’t be able to drive the car until it’s already yours. I’ve heard a number of horror stories from DIY importing. A car that’s already imported, either by a dealer or privately, saves a lot of time and hassle and you can actually drive and inspect the car you want to buy. Finally, remember that these are hard cars to live with. They’re impractical, hard to maintain, and old. But any of the ABC cars is a blast to drive and people ask about them all the time. I highly recommend getting an ABC kei car, just be prepared for what you’re getting into.

      Reply
  2. Khiem Dinh says:
    July 21, 2025 at 7:28 am

    That fuel pump was plenty for Project S2000 with the turbo added, so you’ll have all the headroom you need for more power 🙂 While the fuel system wasn’t the root cause of your issue, it was good to upgrade everything on a car that old!

    Reply

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