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-Where Do the thermostat hoses go? there are 3 medium sized ports and a small (3/8"?)
The middle port bypasses water directly from the head to the water pump during warmup. The bypass hose is a short elbow-shaped hose with different sized ends. As the thermostat opens, it closes off a passage, which causes the water to flow from the head to the radiator inlet (top) through the opening closest to the head. Cooled water then returns from the radiator lower opening through the thermostat port furthest from the head, and flows to the water pump through the bypass hose. A hose barb on the block near the oil pressure sender supplies warm water for the heater (the '75 "E" block has a larger hole for this barb. Earlier blocks have a small drain hole). The small port on the water pump inlet returns water from the heater core.
-What size should I use for the fuel pressure and return line? I have heard of people using brake line, doesn't seem like it would handle enough volume.
Brake line would be way too small. Use 5/16".
-Why is there a fuel pressure regulator needed by the pump? is it accurate and reliable? I was told to have it set at around 30 psi that seems too low considering the system needs more than that at the injectors.
The fuel pressure regulator not only sets the pressure, but it also attempts to maintain a constant pressure differential between the fuel line pressure and the intake manifold pressure. You can see the effect if you pull the vacuum hose from the regulator at idle. The regulator "thinks" the manifold is now at atmospheric pressure and increases the pressure accordingly to maintain consistent fuel delivery. The car runs rich.
-Is the fuel pressure regulator at the fuel rail reliable and accurate?
In my experience, yes. Fuel pressure should be between 31 and 44 psi depending on manifold vacuum.
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