5.0 swap fuel system

[Fletch!]

I have a 2002 2.3 ranger with a return-less fuel system and a 1998 explorer donor vehicle with a return line setup. What will I need to do to run the return lines in my ranger? I have never really done any automotive work besides this swap so I’m not sure what is necessary. I can’t locate the in tank FPR on the explorer fuel pump. Help would be greatly appreciate, after fuel this truck is ready to rip!

 

[JoshT]

You may be in luck. I'm not sure about the 96 & 97, but with a 98 you've got two options. Either you can add a return line, or you can swap a 99+ returnless rail AND injectors into your truck.

If you want to add a return line your pump and supply line will work, you've just got to plumb in a return from the rails back to the tank. Your fuel system provides more than enough pressure (~65 PSI) for the earlier style system (~45 PSI). The 98 5.0L fuel pressure regulator is on the rail, so it's with the engine and knock pressure down to the needed 45 PSI. You'll have to figure out how to actually dump the return fuel back into the tank. Some people try to tie into a vent line, some into the filler neck, and other add a return port into the tank or sender. Never messed with it my self to know what works best.

In 99 the Explorer 5.0L went to returnless like your truck. Runs at the same PSI as your truck. When they went to returnless the fuel pressure increased, but they installed smaller injectors so that the fuel delivery remained the same at the higher fuel pressure. Again you'd need to install a 99-01 Explorer 5.0L returnelss fuel rail and matching fuel injectors, then just attach it to your factory fuel line.

I did look into this myself in the past. I had the 98 return style engine going into a returnless 99 Ranger. On recomendation of people very knowledgeable about Explorers, I was going to convert engine to returnless like I described above. For various reasons, I ended up with a second 2000 Explorer donor that had the returnless engine and used that that whole drivetrain instead.

 

[Fletch!]

You may be in luck. I'm not sure about the 96 & 97, but with a 98 you've got two options. Either you can add a return line, or you can swap a 99+ returnless rail AND injectors into your truck.

If you want to add a return line your pump and supply line will work, you've just got to plumb in a return from the rails back to the tank. Your fuel system provides more than enough pressure (~65 PSI) for the earlier style system (~45 PSI). The 98 5.0L fuel pressure regulator is on the rail, so it's with the engine and knock pressure down to the needed 45 PSI. You'll have to figure out how to actually dump the return fuel back into the tank. Some people try to tie into a vent line, some into the filler neck, and other add a return port into the tank or sender. Never messed with it my self to know what works best.

In 99 the Explorer 5.0L went to returnless like your truck. Runs at the same PSI as your truck. When they went to returnless the fuel pressure increased, but they installed smaller injectors so that the fuel delivery remained the same at the higher fuel pressure. Again you'd need to install a 99-01 Explorer 5.0L returnelss fuel rail and matching fuel injectors, then just attach it to your factory fuel line.

I did look into this myself in the past. I had the 98 return style engine going into a returnless 99 Ranger. On recomendation of people very knowledgeable about Explorers, I was going to convert engine to returnless like I described above. For various reasons, I ended up with a second 2000 Explorer donor that had the returnless engine and used that that whole drivetrain instead.

So all I would need to do is run a return line?

 

[NottaCarGuy]

I have a similar question: I am using a 97 Explorer donor to swap into my 98 Ranger. I know I need the fuel rail from a 99+EX (already purchased), but do I definitely need to buy injectors for a 99+EX or will the injectors from the donor work? Also, in one of the main articles on the subject it states "Use the in-tank fuel pressure regulator from an Explorer pump assembly with 1996-1998 Explorer 5.0L engines." I assume I need to do that in addition to using the returnless style fuel rails?

 

[lil_Blue_Ford]

I have a similar question: I am using a 97 Explorer donor to swap into my 98 Ranger. I know I need the fuel rail from a 99+EX (already purchased), but do I definitely need to buy injectors for a 99+EX or will the injectors from the donor work? Also, in one of the main articles on the subject it states "Use the in-tank fuel pressure regulator from an Explorer pump assembly with 1996-1998 Explorer 5.0L engines." I assume I need to do that in addition to using the returnless style fuel rails?

Are you sure your Ranger is returnless? I’ve seen some that have a return line and some that are returnless for the 98 model year of the Ranger. That is what determines things.

You have to use the correct injectors. If your Ranger has the returnless system and PATS, a 97 donor is a poor choice. If the Ranger does not have PATS and does have a return system (two fuel lines connected to the rail), then you can make the 97 work easily. If no PATS and a returnless system you’re gonna need to do some things.

The 96-98 Explorers with the return system used a regulator on the fuel rail, not on the pump assembly.

The “returnless” systems have a return off the fuel filter and a regulator on the fuel pump assembly.

 

[NottaCarGuy]

Are you sure your Ranger is returnless? I’ve seen some that have a return line and some that are returnless for the 98 model year of the Ranger. That is what determines things.

You have to use the correct injectors. If your Ranger has the returnless system and PATS, a 97 donor is a poor choice. If the Ranger does not have PATS and does have a return system (two fuel lines connected to the rail), then you can make the 97 work easily. If no PATS and a returnless system you’re gonna need to do some things.

The 96-98 Explorers with the return system used a regulator on the fuel rail, not on the pump assembly.

The “returnless” systems have a return off the fuel filter and a regulator on the fuel pump assembly.

Yes, positive my Ranger is returnless and it does not have PATS. I have a 98 2.3L 2WD RCLB. My understanding from this post (see quoted excerpt below) and from other research is that I need only swap the rails from the donor (97EX) with the rails from 99-01EX since those model years had a returnless system. Thanks for confirming I need to get matching injectors - I assumed as much since they changed injectors for those model years. I'm trying to determine what else I need to do, if anything, to address the PSI issue that is raised in the italicized statement below. Sounds to me like I need to use the fuel pump from the 97 Explorer to make sure the pressure matches.

"Fuel System:

The 1999+ Explorer fuel system is a returnless (no fuel return line to tank) and runs at 65 PSI just like a 1998+ Ranger. Earlier Explorer engines (1996-1998) run at a lower pressure and use a fuel return line. For the return line, you have two choices. Run a return line or use 1999+ Explorer rails which are returnless. Use the in-tank fuel pressure regulator from an Explorer pump assembly with 1996-1998 Explorer 5.0L engines. That is very important, as the 4.0L Ranger in-tank pump is set to ~60psi and the Explorer 5.0L pump is set to ~42psi."

 

[NottaCarGuy]

Unfortunately there is seemingly no perfect donor choice for a 98 Ranger. 99+EX you have to deal with PATS and swap the steering column. 96-97EX you have to deal with the differences in the fuel system and the alternator wiring.

 

[lil_Blue_Ford]

Yes, positive my Ranger is returnless and it does not have PATS. I have a 98 2.3L 2WD RCLB. My understanding from this post (see quoted excerpt below) and from other research is that I need only swap the rails from the donor (97EX) with the rails from 99-01EX since those model years had a returnless system. Thanks for confirming I need to get matching injectors - I assumed as much since they changed injectors for those model years. I'm trying to determine what else I need to do, if anything, to address the PSI issue that is raised in the italicized statement below. Sounds to me like I need to use the fuel pump from the 97 Explorer to make sure the pressure matches.

"Fuel System:

The 1999+ Explorer fuel system is a returnless (no fuel return line to tank) and runs at 65 PSI just like a 1998+ Ranger. Earlier Explorer engines (1996-1998) run at a lower pressure and use a fuel return line. For the return line, you have two choices. Run a return line or use 1999+ Explorer rails which are returnless. Use the in-tank fuel pressure regulator from an Explorer pump assembly with 1996-1998 Explorer 5.0L engines. That is very important, as the 4.0L Ranger in-tank pump is set to ~60psi and the Explorer 5.0L pump is set to ~42psi."

Ok, so I think I understand what they are getting at. Swapping the rail and changing the fuel pressure regulator so that it works without changing a bunch of stuff. Only problem is that I’m not sure if the regulator from the rail of an Explorer would work on the pump of a Ranger.

That said, nobody has ever been able to explain to me why you couldn’t pull the regulator off the Ranger pump, hook your return up there and run it to the rail, then just do a single in/single out fuel filter like the 97 and older Rangers. Or for that matter using all of a 97 Ranger’s fuel stuff.

 

[NottaCarGuy]

Ok, so I think I understand what they are getting at. Swapping the rail and changing the fuel pressure regulator so that it works without changing a bunch of stuff. Only problem is that I’m not sure if the regulator from the rail of an Explorer would work on the pump of a Ranger.

That said, nobody has ever been able to explain to me why you couldn’t pull the regulator off the Ranger pump, hook your return up there and run it to the rail, then just do a single in/single out fuel filter like the 97 and older Rangers. Or for that matter using all of a 97 Ranger’s fuel stuff.

I think that’s what they are saying - have to use the pump from the Explorer. Then everything is Explorer and works as expected. At least that’s my working theory. We will see how it goes when I actually get into it. Cant use all the Rangers fuel stuff because obviously the rail needs to marry up to the engine, and I’d imagine the computer is expecting something specific from those injectors.

 

[lil_Blue_Ford]

I think that’s what they are saying - have to use the pump from the Explorer. Then everything is Explorer and works as expected. At least that’s my working theory. We will see how it goes when I actually get into it. Cant use all the Rangers fuel stuff because obviously the rail needs to marry up to the engine, and I’d imagine the computer is expecting something specific from those injectors.

I’m saying I don’t understand why the idea of trying to adapt the Explorer pump when a 97 Ranger pump should be a drop-in change

 

[NottaCarGuy]

I’m saying I don’t understand why the idea of trying to adapt the Explorer pump when a 97 Ranger pump should be a drop-in change

Yeah, very fair. I’ve seen people say that all they did was use 99+ rails and it worked. Wishing I had a 99 or 2000 Ranger right about now.

 

[lil_Blue_Ford]

Yeah, very fair. I’ve seen people say that all they did was use 99+ rails and it worked. Wishing I had a 99 or 2000 Ranger right about now.

I’m not sure how you could do the 99+ rails without doing something to adjust the fuel pressure. That requires changing the regulator on the fuel pump assembly. The Explorer didn’t use a regulator on the fuel pump assembly.

I‘m also not sure why on a 98 that has no PATS you couldn’t use essentially a 97 Ranger pump assembly, filter and fuel lines to match the stock fuel system for a 97 Explorer motor. Be simpler than adapting an Explorer system somehow.

 

[NottaCarGuy]

I’m not sure how you could do the 99+ rails without doing something to adjust the fuel pressure. That requires changing the regulator on the fuel pump assembly. The Explorer didn’t use a regulator on the fuel pump assembly.

I‘m also not sure why on a 98 that has no PATS you couldn’t use essentially a 97 Ranger pump assembly, filter and fuel lines to match the stock fuel system for a 97 Explorer motor. Be simpler than adapting an Explorer system somehow.

True (regarding lack of regulator on Explorer fuel pump), which makes the whole statement from that article questionable. I'm honestly at a loss on this issue at this point. I've been watching a lot of YT videos done by SBS Auto and he maintains that a 97 Explorer is the wrong donor year for a 98 Ranger, regardless of the PATs issue. While many are saying the solution is to use returnless rails and injectors from a 99+, he is also saying you then need a matching ECU. I'm honestly thinking of selling the 97 Explorer donor at this point and trying to find a 99-01 donor instead. Better to do that now before I get into it and past the point of no return.