How many of you guys are running a returnless fuel line in your LS1 third gen? I have seen many with out a return line, but I have heard I must use a return line because my car had TPI (which had a return line). Did the cars with out a return line, start as non tpi cars, or did they make new lines?

Thanks

 

most people running the returnless system have swapped the whole 4th gen fuel system in(tank,lines etc..)

 

I used a vette regulator/filter located near the tank on mine, one line to the engine.

 

Using the 4th gen tank was going to be my suggestion. It fits perfectly. You have to trim a bit off the filler neck (rubber hose)...but other than that its good. Then I used the stock 4th gen fuel lines as well. All the connections at the tank were good. And the lines fit until you get towards the front. I ended up just cutting them and using good stainless compression fittings to re-join them.

This is how they come out in the engine bay. Right were the stock 4th gen had them. They clear the steering shaft and the stock LS1 fuel hook ups work great.





For me...it made wiring easier too. I took out the stock 3rd gen connector behind the seats, enlarged the hole, and installed the 4th gen connector. That gave me all the wiring I needed to run up to the front and make my connections. Since I kept the EVAP system...this made hooking that up a breeze as well.



Justin

 

I too am running returnless. I also used the 4th gen gas tank.

BTW- if you do this, try to get a tank from a later 4th gen car (01, 02) as these had the rubber filler neck section that takes minutes to modify and much easier to install. The early 4th gen tank filler necks were still all metal which requires more work and can be potentially more dangerous to modify.

The problem is the filler neck is longer than the 3rd gen so it'll stick out if not shortened.

Attached is a pic showing my 1984 3rd gen (rusty metal) tank against the 2002 4th gen (plastic- can't rust) tank. note on the 4th gen the filler neck is removed- because it's a rubber part which can be easily shortened.

Like Justin's (Ghettocruiser) car, I too modified the 4th gen lines to work in my car as well as the plug for all the evap/ emmisions plugs. As mentioned it was easy to hook up and if in the future it needs to come apart it too will be easy and replacable.

 

Good point on the years. My tank was from a 99 and it had a rubber neck. Not sure but I think 99 is the cutoff year. Anything 99 + should be a rubber neck. Just dont cut too much like me!! I had to order a new filler neck from GM. It was cheap, but still a PITA.

Good point on future repairs too. The easier it is to go together, the easier it will be to take apart if you need to. If I have to chance pumps, or whatever, everything just comes off just like it would on a factory car. The hoses unclip, the plugs un-plug, etc etc.

Justin

 

Pretty sure all the plastic tanks (99+) had the rubber filler. The 98's were still a metal tank and had metal filler.

Hell I'd use the plastic tank just because it's so much easier to R&R the tank without worrying about the filler neck bending.

Kevin D.