What do I do with stock 5.3L fuel regulator for my swap?

[derotoreut]

I'm doing a 5.3L vortec LM7 swap and installing rear fuel tank with Walbro in-tank pump and Corvette filter with return. So what do I do with my current fuel set up. I have little to no knowledge of these swaps. Learning as I go here, so be gentle. Lol. I assume the upper 3/8" line is the fuel supply and the lower 5/16" is the return. Do I plug the lower 5/16" return line since it won't be used? Can I just remove the vacuum line going from rail to intake? And plug each end?

Assuming upper 3/8" line is feed and lower 5/16" was original return. Can I plug the return with high pressure fitting?


Is this part of fuel regulator? Can it be removed and do I need to plug off upper and lower vac ports?


This one is cracked.

[rennat_2006]

Find a 04 if i remember right or newer truck fuel rail, they are returnless. Should be easy to find and cheap at your local wrecking yard.

[ls1nova71]

You could just use it, it's a better control of fuel pressure and you dont need the more expensive Corvette filter, but if you're set on not using the return, then the only really right way is to do as suggested and find a newer returnless rail. Some will say to cap the return, but that's sketchy in my opinion. Also you will want to let your tuner know you are using a returnless set up since the tune is different between the two.

[derotoreut]

The tuner has the program set up for a returnless system. I thought if I used a high pressure fitting I could cap off the return line, but if it’s an issue of safety then I don’t want to do that.

Please confirm what I should be looking for if I need returnless rails. Remnant-2006 seems to recall 04 and up, but sounds unsure. Or should I be looking for something new (Summit, Jegs, or otherwise)? Thanks.
Posted via Mobile Device

[mongocanfly]

I know opinions vary..and there may be a more right way to do it ...but on my return rail I used a 5/16 pushlok to -an....and then put a -an cap on it ....been about 8-9 yrs now and no issues....

[derotoreut]

Originally Posted by mongocanfly

I know opinions vary..and there may be a more right way to do it ...but on my return rail I used a 5/16 pushlok to -an....and then put a -an cap on it ....been about 8-9 yrs now and no issues....

That's what I was originally planning to do. What about the small tube running between rail and intake? What do I do with that? It snaps into the rail.

[mongocanfly]

I'd have to look but I dont think I did anything with it...

[ls1nova71]

That's just a vacuum hose between the intake and the regulator, it just pulls off. As for capping the return line, its the regulator you need to watch out for. When they go bad, they leak through the vacuum hose and the fuel gets sucked into the intake and makes the engine run rough, so you generally look into it. But if its just left alone and it starts to leak, you probably wont know it for a while, and fuel leaking on a hot engine is a bad deal. I have personally watched my Nova burn, and can tell you from experience that it is not a good feeling. I was lucky, if you want to call it that, in that it was electrical and not fuel related, as fuel fires burn hot and quick. To me a fuel system really isn't the place to cut corners, especially now with how easy and cheap these engines are to find in the junk yards, I probably saw 10 of them this last weekend at the pick n pull half off sale. Getting a returnless rail is the way I would go.

[rennat_2006]

I confirmed it is 2004 and newer are returnless systems.

You can buy a plate/plug deal to replace and cap the hole where the regulator is on the 03 and older return style rails IF you are regulating the pressure with a vette regulator or aftermarket regulator. Just plug the vacuum port on the intake manifold and your good there.

[derotoreut]

Originally Posted by rennat_2006

I confirmed it is 2004 and newer are returnless systems.

You can buy a plate/plug deal to replace and cap the hole where the regulator is on the 03 and older return style rails IF you are regulating the pressure with a vette regulator or aftermarket regulator. Just plug the vacuum port on the intake manifold and your good there.

So does this mean you remove the regulator totally and replace it with some type of plug? Do have any pictures or links as to what you are referring to?

[rennat_2006]

Originally Posted by derotoreut

So does this mean you remove the regulator totally and replace it with some type of plug? Do have any pictures or links as to what you are referring to?

Thats correct
https://www.performancetrucks.net/fo...buy-one-544768

[derotoreut]

Just to bring closure to this thread I decided to go with some newer returnless style fuel rails. IMO this was the better way to go for safety, functionality and appearance. They have been cleaned, painted and now installed.