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1997-1999 4.0 OHV fuel rail differences


zwsmith81

Active Member
TRS Event Participant
Joined
Sep 27, 2023
Messages
28
Age
43
City
Sugarcreek Ohio
Vehicle Year
1997
Engine
4.0 V6
Transmission
Manual
Total Lift
4 inch suspension 3 inch body
Tire Size
33x12.50 R15
I need some help on this fuel rail, regulator, top plenum clearance issues. I’m doing a 99 non egr 4.0 OHV swap in my 97 egr 4.0 OHV. My 97 has the two fuel lines. The 99 has one line with a smaller regulator at the supply port. I swapped the 97 fuel rail on to the 99 so I had my return line. Now my non egr plenum is hitting the regulator and won’t bolt up. Has anyone else ran into this issue? Should I try to upgrade my fuel pump to the single line like the 99 or is there a way to modify the plenum to fit over the 97 regulator?
 
Disregard this, I just figured out what I did wrong!!
 
That’s not a regulator on the 99 return less fuel system rails. That a pulse damper. It’s basically a small accumulator that absorbs the pressure spike in the system as the injectors close.
 
@zwsmith81
Why not use the 97 intakes and fuel system on the 99 engine?
 
That’s not a regulator on the 99 return less fuel system rails. That a pulse damper. It’s basically a small accumulator that absorbs the pressure spike in the system as the injectors close.
That’s a good thing to know. Thanks!
 
@zwsmith81
Why not use the 97 intakes and fuel system on the 99 engine?
That’s what I’m doing. I had a total brain fart and had installed the fuel rail backwards. That’s why the plenum hit the regulator. Switched it around and everything bolted right up!
 

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