99 mustang 3.8 fuel system conversion

Just wondering. Does this car have to pass an ODB2 inspection in your area?

Have you also searched car-part.com for a replacement gas tank from a salvage yard car. Note, you don't have to swap the entire gas tank. The salvage yard unit could be raided for parts to get your tank back into action.

Bsharp21 said:

the fuel pressure regulator for 99+ is in the tank because it is a returnless fuel system, and apparantly this part is not in production anymore not even aftermarket.

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The fuel pressure regulator (FRPS) for the 1999-2004 is located on the fuel rail.

Here's an example replacement



The part at the top of the gas tank is a liquid/vapor separator. The purpose is to keep liquid gas out of the vapor management and charcoal canister. If liquid gas gets into the charcoal canister it will turn the granular carbon to jelly thus blocking the vapor flow.

For the 1999-2004 Mustang there is no pressure inside the gas tank ever. Why? Because the fuel tank is vented through the charcoal canister. So the pressure inside the gas tank is always close to atmospheric. Except during EVAP purge and testing.

But there is a fuel tank pressure sensor that is used during EVAP purge. A replacement fuel tank pressure sensor is hard to find.