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Ford Trucks \  returnless to return conversion

returnless to return conversion

Ford Trucks Make Specific
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low99maz   +1y
Edited: 6/3/2008 5:47:54 PM by low99maz

Was all that work done to the truck before you bought it? Also whats up with your upper c arms? Are you using a stock spindle?
willie_wonka   +1y
If the truck has the stock motor with the stock rails, then originally the fuel pump was controlled by a module that varied voltage to the pump to regulate fuel pressure. If the engine is still stock and controlled by the original ECM then there is a sensor on the rail that tells the ECM what rail pressure is so it can control the pump accordingly. If you want it work worth a shit at all, you should probably get a stock pump in the fuel cell. The ECM (assuming you are still using everything else stock but the tank and pump) is not going to like not seeing a pump or any changes in rail pressure when it commands it. At the very least, you will get a service engine light and probably poor driveability. You say it was running with the return system. I am willing to bet thats what you were told and not what you saw because then the stuff would already be installed correctly. I don't doubt that the truck did run with the external pump and regulator but I am willing to bet it ran like shit. I am not trying to discourage you, alot of race cars(read mustangs) have been converted to return style systems but they also have been tuned by a dyno tuner to do so, either programming the fuel rail sensor and fuel pump driver module out of the equation or ignoring the SES light. When I first read the post I thought the truck had a V8 swap or something like that. I am not trying to sound like I know it all, I may be wrong, but I am a certified Ford lead tech and I have built a few mustangs as well.
willie_wonka   +1y
I think one line comes from the pump to the regulator and one goes from the regulator to the rail and one goes from the regulator back to the return on the fuel cell. This is how aftermarket pressure regulators for carbureted cars work and a returnless rail is like a carb because it doesn't have a return either, but regulators for carbs usually regulate pressure to like 5psi or less which is waaay to low to make the motor in the Ranger run. Good luck with your truck and I hope I have been of at least some help.
unusualfabrication   +1y
^^^^right on! On a carbed motor it goes tank, filter, pump, regulator, carb, then the second line goes back to the tank. My SBC runs around 6.5 psi.
ixenn   +1y
Edited: 6/4/2008 2:18:03 AM by ixenn

dropping a stock setup will require a new fuel cell. And I don't know why they disconnected it but maybe you are right. Ill see what I see i suppose I can take some pictures tomorrow and let you guys tell me if its the stock rails and ill go from there. I don't mind getting it tuned for the ext. pump and shit because i really don't want to buy alot more stuff

I see how the system should be but i don't understand how it would work as there is two inputs and only one output - the method you mentioned requires two outputs and one input right?
ixenn   +1y
Edited: 6/11/2008 5:10:11 AM by ixenn

Edited: 6/11/2008 5:05:29 AM by ixenn

ok I have to get this going so I took a lot of pictures hoping you guys can help me better

top view of tank - I don't see anyway to fit a stock pump and reg. in there?

125psi pump with flow going towards engine pulling from bottom of tank

where fuel comes from - will this work?

Questionable port by EGR valve - any clue what this is?

Top view of motor where fuel line enters rail - does this look like a stock 2000?

Closer view of inlet.

Stock fuel line which will go to the pump.

Another view of inlet and top of engine.

The regulator again.

Seeing all of this what is the recommendation?

I am thinking fuel pump - fuel filter - fuel regulator - fuel rail inlet and getting someone to disable the pump control from the ECU? I really need help.
ixenn   +1y
no clue? any things to look for to see if maybe they installed an older fuel rail??
ixenn   +1y
i really need to figure this out :\
low99maz   +1y
My 99 although it is flex fule has all the same lines, the two hard lines that you have looped run under the manifold
low99maz   +1y
I would just cut a hole in the top of your tank and bolt down the stock unit with a gasket, problem solved!!