Converting 2016 Ram 1500 to return style fuel system.

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Josh22855

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In the process of installing a return style fuel system on my Ram 1500, few snags along the way so far.

You can get away with a single pump and a non return style fuel system for about 600WHP, I pushed my single pump setup to roughly 675whp with the help from a boost a pump but the fuel pressure and injector duty was showing scary #'s. I do not want to gamble with the life of my engine any longer. Time to let her drink!

I had bought the fore innovation fuel rails for my truck (stock intake manifold), when trying to get the injectors on the driver side to seat off I noticed that the front injector would not go all the way down because the fuel rail was making contact with part of the intake manifold. I have FIC 1000 injectors and they are 48mm in length just like the stock ones. I reached out to fore innovations and they are definitely taking care of me. They are sending me fuel injector spacers, this will lengthen the injectors to 60mm and this will allow the injectors to seal off and give some clearance between the fuel rail and the intake manifold. In addition they are sending me spacers to go between the fuel rail and manifolds as well as longer bolts.

Picked up an awesome fuel pump assembly (basket and all) from modern muscle extreme.
"2009-2016 Dodge Ram Truck Dual Pump Fuel System by MMX"
As well as the relay box.

Running -8 socketless fuel line for my supply and using the stock supply fuel line as my new return line.

I had to remove the fuel level sensor off the stock basket and transfer it over to new pump basket.

When the parts come in from fore innovations I will complete the build. I'll post some pictures when complete.


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Wild one

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In the process of installing a return style fuel system on my Ram 1500, few snags along the way so far.

You can get away with a single pump and a non return style fuel system for about 600WHP, I pushed my single pump setup to roughly 675whp with the help from a boost a pump but the fuel pressure and injector duty was showing scary #'s. I do not want to gamble with the life of my engine any longer. Time to let her drink!

I had bought the fore innovation fuel rails for my truck (stock intake manifold), when trying to get the injectors on the driver side to seat off I noticed that the front injector would not go all the way down because the fuel rail was making contact with part of the intake manifold. I have FIC 1000 injectors and they are 48mm in length just like the stock ones. I reached out to fore innovations and they are definitely taking care of me. They are sending me fuel injector spacers, this will lengthen the injectors to 60mm and this will allow the injectors to seal off and give some clearance between the fuel rail and the intake manifold. In addition they are sending me spacers to go between the fuel rail and manifolds as well as longer bolts.

Picked up an awesome fuel pump assembly (basket and all) from modern muscle extreme.
"2009-2016 Dodge Ram Truck Dual Pump Fuel System by MMX"
As well as the relay box.

Running -8 socketless fuel line for my supply and using the stock supply fuel line as my new return line.

I had to remove the fuel level sensor off the stock basket and transfer it over to new pump basket.

When the parts come in from fore innovations I will complete the build. I'll post some pictures when complete.


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Out of curiousity what's this set you back so far?
 
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Josh22855

Josh22855

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Out of curiousity what's this set you back so far?

2500 is a real close dollar amount.
Dual pump assembly/fuel filter/fuel rails/ fuel sensor/ fuel sensor harness extension/ AN/ORB/socketless fittings/ regulator/hoses.

Gunna spray the 16psi boost with some chilling nitrous when it's all said and done! (Dry shot)

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Wild one

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2500 is a real close dollar amount.
Dual pump assembly/fuel filter/fuel rails/ fuel sensor/ fuel sensor harness extension/ AN/ORB/socketless fittings/ regulator/hoses.

Gunna spray the 16psi boost with some chilling nitrous when it's all said and done! (Dry shot)

View attachment 246376

You want that picture with the front wheels in the air a foot don't you,lol
 

James OBrien

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I'm basically embarking down the exact same path as you because my truck finally surpassed the ability of the stock pump and BAP, my regulator is failing. Bought the same dual pump setup, did you end up removing the stock fuel pressure sensor or keep it in the return path?
 
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Josh22855

Josh22855

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Remove your stock fuel pressure sensor and trash it, use your old supply line as your new return line. You will need a 3/8 quick connect to most likely 6AN (that's what I used) fitting in the place of the old pressure sensor. You can get the aftermarket pressure sensor and wire extension from TappedPerformance.com, the owner here is VERY helpful.
Remember to regulate your fuel pressure AFTER the fuel rails.
 

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Fast69Mopar

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Regulator mounted on the side of fuse box.
I do my return style systems just like you explained with the stock fuel line as the return and I ditch the stock fuel pressure sensor. I have purchased several of the fuel pressure sensors and wiring harness extensions from tappedperformance.com

One fuel filter I have been selling and installing lately for my budget builders and racers has been from Evil Energy. They are only $25.99 and I can have them next day. They are 50mm in diameter and they are a 100 micron filter.
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Here is a link to the budget filters...

 

James OBrien

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I'm having a heck of a time finding a compatible fuel rail for our stock truck intakes, what did you use exactly?
 
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Josh22855

Josh22855

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Fore Innovations Fuel Rails (2005-2020 5.7L/6.1L/6.4L HEMI Vehicles) - HFR - 11-900
 

James OBrien

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Hopefully final question; on the Fore fuel rails did you go with the 48 or 60MM injector length option? I read that you mentioned 60 and had to get spacers?
 
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Josh22855

Josh22855

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I have the 48mm injector length (Fic1000's are same length as stock). If your injectors are 48mm you will need this kit here from Fore innovations. As you can see in the picture (on page 1) it is just that blue sleeve that slides over the tip of the fuel injectors.
 

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