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Wanting to go to a return style fuel system on my 04 C5 which has the factory returnless setup. I can't seem to find much info on how to basically do this except I see the older C5 has an external fuel filter with the return hose fitting on the filter.....hmmm, so is this where you plumb the return line or what else is involved? Thanks much guys.
alot of the time people use the factory lines as the return line and add a new supply line. You need a bigger supply than return is my understanding.
Ok but how is it all plumbed in? Like does the return come from the rail back to the tank? How come the older C5 fue filters have the return on the filter itself? Sorry I am confused by this :p
Here is pic of my old AA fuel system. Return line go fuel rail schrader valve to regulator, regulator line is connected to fuel filter return line. You just have to change 97-98 fuel filter. I am not sure did AA corvette still sell this kind fuel lines.
Last edited by Vette97sc; Jul 20, 2021 at 12:37 PM.
I'm not sure if there are any filter differences with the 03+-04 tank setup which need to be considered.
In a simplified list:
-need a 97/8 filter
-need a rail setup that allows a return (99+ rails are feed only) *note, the factory 97/8 rail has a regulator built in - it's a unicorn part these days - After market rails will require an external fuel pressure regulator.
-return line run to the tank/filter area
That's really all it is - Just a matter of sorting how this aligns with the 03+ tank setup. Plenty of people have done it - Plenty of vendors have kits...
The 2003 and 2004 C5 fuel system is a bit more complicated then some have said. Here is a link to my build page. https://www.corvetteforum.com/forums...-fi-build.html
The link should give you some ideas on the fuel system. I did a return style with a walbro 525 pump. I'm at a little over 700rwhp on 93. I'm good to go on fuel pressure. However if I went to E85 I would not have enough pump, even if I added a BAP.
First you will not have enough fuel pump even with the BAP running E85 at 650.
You are going to need twin in tank pumps( ie: FORE innovations) or an intank pump and an external pump (ie: A&A set up or ECS set up). You can also talk to Blownbluez06 (Bret) about a fuel system. Bret can build you anything you want.
Anyway you look at this you will need a hobbs switch or controller, well unless you run both in tank pumps all the time or have a one big *** pump which I do not recommend.
The 2003 and 2004 C5 fuel system is a bit more complicated then some have said. Here is a link to my build page. https://www.corvetteforum.com/forums...-fi-build.html
The link should give you some ideas on the fuel system. I did a return style with a walbro 525 pump. I'm at a little over 700rwhp on 93. I'm good to go on fuel pressure. However if I went to E85 I would not have enough pump, even if I added a BAP.
First you will not have enough fuel pump even with the BAP running E85 at 650.
You are going to need twin in tank pumps( ie: FORE innovations) or an intank pump and an external pump (ie: A&A set up or ECS set up). You can also talk to Blownbluez06 (Bret) about a fuel system. Bret can build you anything you want.
Anyway you look at this you will need a hobbs switch or controller, well unless you run both in tank pumps all the time or have a one big *** pump which I do not recommend.
Let me know if you have any questions.
KT
Thought I'd come back to my thread instead of making a new one
So I'm currently doing the whole nine yards for my E85 conversion, etc. Running a 8AN feed and 6AN return, etc.
My question is, will I be okay with just one Aeromotive fuel filter up front (10 Micron stainless steel) or do I need two like some diagrams show?
Last edited by vettefx76; Jun 9, 2022 at 11:31 AM.
i'd PM BlownBlueZ06... he builds fuel systems day in & day out.
so far, the return conversion he did on my 2000 is working well (almost 4yrs now), and i believe it's just got the one 97-98 filter behind my front fender.
i'd PM BlownBlueZ06... he builds fuel systems day in & day out.
so far, the return conversion he did on my 2000 is working well (almost 4yrs now), and i believe it's just got the one 97-98 filter behind my front fender.
No Thanks - sorry but I did not really get anywhere with Brett aka BlownBlueZ06. I did talk to him on the phone for a long time once and in all honesty he did not want to give me a straight forward answer on how to do anything myself but instead tried to up sell all kinds of stuff to me and was going on and on about how good he is and how bad *** his million dollar shop is, etc. etc. to the point where I was beginning to wonder wtf was going on here. It was sort of like "oh you buy this first then I will tell you more and we will go to the next step til then we are going in circles about nothing lol"...
Maybe you and many others had a good experience and that's great but I'll pass on that guy. After many months I finally figured it all out and with the help of other GREAT forum members on here and Ls1Tech it has all come together and it's crazy how simple this is and I will "spill the beans" to anyone wanting to do it and have some know how instead of beating around the bush...
Last edited by vettefx76; Jul 13, 2022 at 03:05 PM.
Hey bro, I’m just getting started on my install. Can you tell me what all you’ve done?
Sure!
I dropped both gas tanks and installed a Chris1313 dual pump kit. Also replaced all the seals on the crossover tube.
Then I ran a 8an feed and 6an return ptfe braided line to the front. Used a 8an Y to feed both rails on the back. Installed a regulator on front of the rails.
The return line goes to the regulator bottom and you will have to make two short lines for the front of the rails to each side of the regulator. Tuner told me to set it at 58psi.
Also I installed a Aeromtive filter on the feed, near the gas tank. Aeromotive has diagrams how to do this.
It's alot of work and can get costly but it's the best you can do for the fuel system if you are trying to make some power.
Last edited by vettefx76; Jan 3, 2023 at 10:01 PM.
I got mine finished finally. It is the Bret design for the 03-04. Finally finished I can say it is actually dead easy and simple concept once you go through it.
I'm a "Lego" dude. I don't need to know everything if you give me instructions and a few pictures because I will figure it out and get it done easily. Without an instruction guide and with my work schedule and his own being often opposite it was a lot of small conversations going over this or that piece when we could and me looking at a pile of 500 parts not wanting to screw it up and have to re-do any pita portion. I guess some less technical clients have had trouble with this kit/concept and that makes sense to me if they have no written guide, so he doesn't really offer the kit anymore because of it. I had documented 2/3 of it on my little builder box PC in the shop as a guide he could give to clients but the memory card died. I haven't gone back to recreate any of it.
I got mine finished finally. It is the Bret design for the 03-04. Finally finished I can say it is actually dead easy and simple concept once you go through it.
I'm a "Lego" dude. I don't need to know everything if you give me instructions and a few pictures because I will figure it out and get it done easily. Without an instruction guide and with my work schedule and his own being often opposite it was a lot of small conversations going over this or that piece when we could and me looking at a pile of 500 parts not wanting to screw it up and have to re-do any pita portion. I guess some less technical clients have had trouble with this kit/concept and that makes sense to me if they have no written guide, so he doesn't really offer the kit anymore because of it. I had documented 2/3 of it on my little builder box PC in the shop as a guide he could give to clients but the memory card died. I haven't gone back to recreate any of it.
Nice!! my 03 needs a nice brent fuel system update I already have the cradles dropped and drivetrain out. Brent is the man! What setup did you go with and how much fold?
If you run dual pumps you want 1 pump running and 1 pump on stand-by for WOT conditions such as Xpsi of boost
Running two pumps all the time is wasted pump life, excess fuel heating, reduced fuel system lifespan
I'm doubly excited now because I had built it to handle E85 yet there were no pumps within 90 minutes or more drive of me. Last summer a new station opened with an ethanol pump not twenty minutes from home. So far averaging E60 which is more than I'd need by far anyway. Fun to have the option available now and to have a boosted car to take advantage of it.
C5 returnless to return conversion setup?
instead of beating around the bush...
