How to delete fuel return line on 96 5.0L?

[Blacksheep Josh]

I have an opening to buy a 96 5.0L to install into my 01 Ford Ranger. My Ranger is returnless fuel while the 96 has a return line. Any way to delete that?

 

[koda2000]

having just spent some time inside my 2000 Mountaineer's fuel tank, i can tell you this much. on the return-less system the fuel pressure regulator is part of the in-tank fuel pump/sender assembly. when the pressure reaches it's maximum (i believe around 65 psi) it dumps fuel back into the tank. i understand there's a device up on/near the fuel rail that's referred to as a fuel pressure damper. i assume it's purpose is to prevent pressure spikes.

i do not know if the '96 fuel tank would accept the newer style return-less assembly, or whether/how you could replace your engine mounted fpr with a damper.

 

[SoNic67]

I think you would need to replace the whole gas tank - with all what is inside.
Beside the pump, pressure regulator, level sender (all on one assambly), sump sock not fitting physically, there are other things that might not match - vapor vent, fuel tank vapor pressure sensor...

 

[delexploder]

A 98 fuel rail and injectors

 

[budwich]

yep... cause the pressures are significantly different..... but of course there is more, you will also need a different pcm as a result or at least a reprogrammed one.

 

[delexploder]

Just swap the fuel rail with a 98 it will be fine I had mine running both ways its now set up as a 97. 98 is returnless and will work with your setup the pcm dosent care the only other thing you may have to change is the plugs on the motor harness that go to the injectors. I can look later because I still have all that stuff in my shed

 

[Turdle]

Actually, he will need to swap to 99 up fuel rail and injectors. 98 still had return style system.

 

[delexploder]

Your right Jon I keep forgetting that's what I started with lol now I have a 99 motor with external egr and 97 rail and injectors and all running on a 97 harness with 97 pcm . He's also gonna have pats problems just the opposite of mine

 

[Turdle]

^^good point. I think Blacksheepjosh should try to make the 96 tank ( and 96 fuel lines) work. This would be the smoothest road I think.

 

[delexploder]

he's still gonna have to do something with the patts system that's on the truck side no matter what setup he runs. Knowing what I do now after doing mine he would just be better off with a 01 ex for the donner or get the harness, pcm, patts parts ,fuel rail and injectors from one and put them on the 96 motor and in his ranger as far as the patts modules if the 96 is all he can find .that's why I had to go through all the same crap I just couldn't find a year match local. But even then there still will be bugs and wiring to deal with