I need to figure out the difference between the Return type fuel tank from the 02-03 lancers and the returnless fuel tank of the ralliart.

This is so that I can figure out the last hurdle in my engine swap and get the engine in!

Basically here is the ralliart fuel tank:



Does anyone know what the difference is between that, and what I'm likely to have in my car, which is a RETURN FUEL 4G18.

I'm looking for which ralliart fuel tank parts I need to buy. Im guessing the fuel pump, but Im not sure about the sensors.

If no-one can help me I'll have to buy an 02-03 shop manual.

 

https://www.evolutionm.net/forums/sh...d.php?t=191259

This thread may help you, but I can't answer your question.

 

Fuel tanks are identical. The only difference is the top of the fuel pump housing. The 02-03's have a nipple for the return line. That housing is interchangeable with a Ralliart. Unfortunately, I don't have a picture for reference.

The thread Dan pointed you to is exactly what you need. The Ralliart is very easily converted to a return system, all you need is an Evo fuel rail, a return line, FPR, and a way to connect the return line to the tank. You can either swap the fuel pump housings, or install a fitting on the top of the tank.

 

Ok thanks, I have another question though because I was led to beleive the returnless system was better? But a lot of you guys seem to prefer a return system. Why should I go for a return system?

I'll just make it clear what I'm doing to avoid confusion:

My 05 UK Lancer 1.6L is Return type so my car has all the return stuff on it.
My new 2.4 4G69 engine is obviously meant to be Returnless.

Im essentially trying to convert my fuel tank from return to returnless.

What I dont want to do is confuse the ECM, as the new 2.4 ECM in my car is going to want to control the fuel pressure via the pumps regulator is it not!?


What I think I will do however is just get the ralliart fuel pump, as I believe the ECM controls fuel pressure whereas on the 02-03 and my car it is always the same and any excess is routed back to the tank. Therefore I dont want to throw a CEL by changing to a return system on that engine and ECM.

Finally, if the ECM controls the ralliart's fuel pressure, then is the Fuel Differential Pressure Sensor only on the ralliart tank or is that also on the 02-03?

 

The reason some of us go returnless is that, in stock form, there's no way to control fuel pressure on the RA. When people go turbo, or do anything that requires more fuel, we're left with the issue of how to deal with the fuel supply. Switching to a return system is one way for us to control it, as it allows us to use aftermarket FPRs.

I was confused about which way you were going. If you're going returnless, just get the Ralliart fuel pump assembly and you'll be all set.

For the last question, you'll have to ask one of the 02-03 gurus, my manual doesn't have a diagram for the 02-03s

 

Well thanks for the help, I'll get the ralliart fuel pump and go from there. I've bought a copy of an 02-03 shop manual to try and figure out any other differences.

Just want to limit anything that could crop up whilst were doing the actual swap, which is now quite close.

 

im following your lead on this.! i ALMOST forgot that id need to get the ralliart pump.. Getting the fuel door open is a *****! cuz the bolts are in hard to reach places... hopefully i can still use my high flow Walbro 255Lph Fuel pump.

just get the $10 CD manual from ebay

 

Well when I do the swap I'll take photos of every stage and write it up!

 

Well heres what I found out:

02-03 Tank



04-06 Tank



02-03 Pump



04-06 Pump and Regulator




Basically, I just get the ralliart pump and I'm fine. Everything else seems to be exactly the same.

 

Hey man, how it going cause i will do this conversation soon and i need to know more about how to do returnless fuel pump and install canister

 

10 year old thread...happy new year