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5.0 swap fuel system


Fletch!

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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

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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!

Member
Joined
Jan 7, 2025
Messages
12
Reaction score
0
Location
Ca
Vehicle Year
2001
Make / Model
Ford Ranger
Transmission
Manual
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?
 

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