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Old 10-12-2009
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I am: Rick James
Join Date: Jun 2009
Location: Woodbine, IA
Vehicle: 1998 Ford Ranger XLT
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Icon5 3.0 to 4.0 swap fuel return problem

I am swapping from a 3.0 to a 4.0 and noticed the 4.0 has a fuel return line. I asked Ford about this and they said it is used for pressure to injectors.

I am wondering what I need to buy and do so this will be set up for the 4.0 to be used in the truck. Any information will help with this.

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Old 10-12-2009
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One is a return-type system with the pressure regulator on the fuel rail; the other is returnless with the regulator in the tank. The two systems run at very different pressures and require different flowrate injectors. You must match the pump/lines/regulator/ injectors/fuel rails/PCM from a compatible donor or it won't work.

A 98+ 4.0L will be returnless like your 3.0L but this type of swap is still a minefield of potential problems. Staying with the same year donor as your truck is the best way to avoid compatibility issues.

Last edited by rwenzing; 10-12-2009 at 10:54 AM.
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