return fuel system to returnless

[terrylgreenjr]

I have all the fuel lines set up for a returnless fuel system but I using a 4.8 with a return line fuel rail. Is there a fitting I can use to block off the return line?

[clinebarger]

Originally Posted by terrylgreenjr

I have all the fuel lines set up for a returnless fuel system but I using a 4.8 with a return line fuel rail. Is there a fitting I can use to block off the return line?

Someone would GLADY trade you a returnless rail, With the cost of a "vette" filter.....Its cheaper in the long run to run a return line & keep your fuel rail.

[terrylgreenjr]

As long as the return less fuel rail works with the truck manifold I would trade. Because now I have a headache trying to cap off the return
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[ls1nova71]

I have to agree, just keep your fuel rail, run the cheaper filter and put in a return line.

[terrylgreenjr]

I've already got the filter and lines ran. If I can find maybe a quick connect fitting with threads and just cap it off it would be great
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[ls1nova71]

I don't think you can do that. The return style fuel rail has a regulator on it that the returnless does not. Not sure what you would have to do with the extra regulator.

That said, I'm probably going to be picking up my 2004 5.3 tomorrow and it has a returnless rail and I'm going return style. If you want to work a trade let me know.
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[terrylgreenjr]

The regulator works off vacuum I think without the line hooked to it it goes to full psi. If you want to trade that would be great Keep me posted
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[OneOffStroker]

http://www.ebay.com/itm/OEM-GM-12599...3aee07&vxp=mtr

I bought on of these. You will have to modify the 4 mounting tabs just a tad, because it's a flex-fuel rail, and they have longer injectors, but the mod is super easy. I can take pics of mine and post them if you need me to.

[terrylgreenjr]

If you have pics that would be great. I'm exploring all options right now.
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[terrylgreenjr]

what about using this to cap off the line
http://www.summitracing.com/parts/RUS-640860/

http://www.summitracing.com/parts/RUS-661960/

[OneOffStroker]

I would hesitate to cap off the line. It just doesn't seem right in any way.

Here's some pics of what I did:
1) Since the mounting tabs are recessed, which raises the rail due to the extra length of flex-fuel injectors, I needed a way to lower the rail. I cut wedges out of them so that they fit against the stock mounting bosses.
2) The top of the recess now sits just barely higher than the mounting bosses, which is good, because it will allow me to 'preload' the rail to ensure it isn't loose.
3) I used a large fender washer to cover the flex rail tabs completely and secure it all to the stock intake bosses.
4) A different angle of the finished product.

[clinebarger]

DO NOT cap the return, The regulators are bad about leaking anyway, When dead-headed IT WILL LEAK ALOT if the regulator went bad. You dont want to flood your intake with fuel or your truck to catch fire.

[terrylgreenjr]

So I'm going to have the corvette style filter/regulator and you don't think it would be ok to cap the return line?
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[clinebarger]

Originally Posted by terrylgreenjr

So I'm going to have a regulator on the fuel rail and the corvette style filter/regulator and you don't think it would be ok to cap the return line?
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Ive seen return style LS engines run 45 psi with full vacuum & 55 psi with no vacuum, The Vette filter regulates at 58 psi, So the regulator on the rail will be open ALL the time trying to return fuel....But cant if you have it blocked.

Now if the diaphram in the regulator ruptures/leaks it will leak into the intake if the vacuum hose is connected or on the engine if its not.

[ls1nova71]

I picked up my 2004 5.3 yesterday, only to find out it's actually a 2003, so it doesn't have the returnless rail. Sorry.
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[terrylgreenjr]

anyone have a returnless fuel rail they are wanting to part with?

[terrylgreenjr]

I picked up a returnless rail on CL if anyone needs a return rail system

[Rudy-g]

hey guys i have a 2005 5.3 truck motor, i have the original sending unit to that motor, could i pull the fuel pump out of that unit and maybe retrofit it into a different unit, can i use a regular fuel filter or do i still need the vette style filter?

[ls1nova71]

Originally Posted by Rudy-g

hey guys i have a 2005 5.3 truck motor, i have the original sending unit to that motor, could i pull the fuel pump out of that unit and maybe retrofit it into a different unit, can i use a regular fuel filter or do i still need the vette style filter?

I haven't had an '05 sending unit apart, but I would think it would have a typical looking pump unside it, so you probably could fit it in another sender, but if you have a returnless rail, and I think you would, you'd still need the 'Vette filter/regulator.

[Rudy-g]

Well i guess it wouldn't hurt one way or the other right. and the pump does look like a typical intank pump, ill see what i can do about retrofitting it

[mcmlxix]

I have a 2005 Sierra fuel pump that I will be running in a custom stainless tank. It has an internal filter, internal regulator and the typical looking pump. I purchased a billet machined ring that allows the use of the factory pump. its from www.vaporworx.com and rand me $150 direct from them. You then use a factory $9 cam lock ring to hold it in place. The pro-touring crowd uses this to run the Corvette, Camaro and CTS-V fuel pump (depending on HP). They make the ring in Stainless Steel and Aluminum.

[ls1nova71]

Originally Posted by mcmlxix

I have a 2005 Sierra fuel pump that I will be running in a custom stainless tank. It has an internal filter, internal regulator and the typical looking pump. I purchased a billet machined ring that allows the use of the factory pump. its from www.vaporworx.com and rand me $150 direct from them. You then use a factory $9 cam lock ring to hold it in place. The pro-touring crowd uses this to run the Corvette, Camaro and CTS-V fuel pump (depending on HP). They make the ring in Stainless Steel and Aluminum.

In my opinion this is would be the way to go, especially if you already have the pump and sender since one of the drawbacks is the price of this pump. The plus side is you wouldn't have to run the Corvette filter and you only have to run one line. Tank depth is the other limiting fafactor, but in a truck it usually isn't a problem. I'm running a Racetronix pump in an S10 sender that also is the bucket type in a modified Blazer tank. The bucket senders do away with the need for a baffled tank which is another plus.
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[Rudy-g]

where can i get a tank like yours. or one that i can set up like you did.

[mcmlxix]

I scored the AC Delco pump on ebay for $75. new in the box. I think it was overstock at a dealership somewhere. The depth of my tank will be 13" but the fuel module is designed to telescope on the two rods and you can shrink it down to probably 10" tall. The Corvette / Camaro / CTS-V pumps are shorter and work with the same billet ring if you have a lowered truck and space is an issue.

Also, if I ever have an issue on a trip, I could cough up the $250 and get a new pump at any parts store across the country...