returnless to Return style fuel conversion

[allmyEXes]

Normally I wouldn't revive an old thread, however, this thread is just over 4 years old and 95% of the participants are still around.
I have an issue (another issue), with my 1997 5.0 Mountaineer wasted spark coils to Coil-near-plug conversion. The '97 has an early 104 pin PCM and in my studies of how to go about doing this conversion, many questions have been asked and many things have been learned. One is that the 2003-2004 Marauder PCM is a faster type and the last of the 104 pin PCMs. What I have run into now, and I found this thread by doing a google search, is that I'm probably going to have to switch my fuel system to return-less, the opposite of how this thread was started.
The PCM addresses the pump function and pressures different. I do understand that 'super tuner' guys know how to get into the PCM and make some changes and re-designate a pin? I don't quite understand all of it but my thoughts are that I need to convert to the 2003 fuel pump, make the fuel system return-less and add a Fuel Injection Pressure Sensor. All of these parts for or from a 2003 Marauder to work with the 2003 Marauder PCM. I see many of you have given this general topic of swapping from return-less to return line type a lot of thought. Thanks for any input. Picture of a fuel injection pressure sensor below.

 

[CDW6212R]

Thanks for another thought to work out. I had wondered which fuel system might be best for my projects too, but I was putting it off until I was closer to working on the wiring and fuel. It will be helpful to know which way to go for the later PCM's. I have to rework the fuel rails for my 347 anyway, so I'll decide on what kind of fuel system to build it for then. My BBK SSI intake has two provided nice rails, but the original design has a cross over pipe through the intake port section. I'll plug those holes and be adding AN lines on one end for sure, with a returnless system, I'd only need one line and leave out the FPR at the provided location.

 

[allmyEXes]

The FIPR would have to be incorporated in the assembly. I wondered if the tap with the o-ring would plug into the '97 fuel rail in place of the fuel pressure regulator? I could see having to drill new holes in the 2003 part to fit the '97?

 

[CDW6212R]

I'm not sure what returnless pressure devices can do beyond the OEM type next to the in tank pump. Those control pressure dead heading upstream, while the old return style FPR, those just bleed off fuel as it needs to, to maintain the 35-40psi in just the rails.

 

[410Fortune]

So are you saying in order to use the 03-04 pcm you must add the returnless fuel along with the pressure sensor that mounts to the rail so that the 03-04 Maura see pcm can control the fuel pump?

Why not keep it simple just like the 99-01 returnless system where the pcm just activates the pump and does not control pressure?

The earlier pcm (96-01) simply turns fuel pump relay on and off there is no pressure control built in and we can freely change between the return style and returnless

I have a 03 Taurus 3.0 fuel rail here I do not need it contains that pressure sensor, I can remove it and send it to you if you want to mess around with it?
I put a 03’taurus 3.0 into a 03’ramger 3.0 the fuel rail is left over parts

 

[CDW6212R]

That's what I'm not sure of, I have so much more to do to get to the fuel system and rail, I haven't yet asked about that. I can do it either way since I have to replace the entire system in my Fox chassis Lincoln.

For Greg's Mountaineer and its 97 PCM, the 2003/04 PCM may make it more complicated if it requires more changes to the fuel system. He can use the near stock pump choices, but the returnless questions brings in the FPR, rail sensor, and/or the tank pressure regulator. We should ask M. Decipha that soon.

 

[allmyEXes]

@410Fortune Jamie, I'll take you up on that offer of the Taurus fuel injection pressure sensor. It does have exactly the same part number as the Marauder piece. That will help me a lot as far as sizing everything up. If you could "chop" the rail on each side of the sensor to include the plate on the rail that the sensor bolts to, would be great! I envision a situation where the plate may have to be connected to the '97 MM plate on the rail. I'll let you know a little later about the why of using the 2003 full size PCM. Thanks in advance and let me know about the shipping and your time, I can have brother Ken PayPal you or I can now send funds through Zelle. Y'all stay cool, I hear that we have swapped temperatures with you north westerners.