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Vortec 8100 8.1L V-8 (L18) 2004 Model Year Summary Returnless fuel injection for Chevrolet Avalanche, Silverado and Suburban, GMC Sierra and Yukon XL and Workhorse Custom Chassis Low permeability intake manifold body gaskets Improved onboard refueling vapor recovery (ORVR) system for Avalanche, Silverado, Suburban, Sierra and Yukon XL Exhaust gas recirculation (EGR) eliminated Improved crank and cam timing sensors Improved crankshaft seal Adjustable throttle pedal for Workhorse Custom Chassis Revised cylinder heads for industrial applications FULL DESCRIPTIONS OF NEW OR CHANGED FEATURES RETURNLESS FUEL INJECTION FOR CHEVROLET AVALANCHE, SILVERADO AND SUBURBAN, GMC SIERRA AND YUKON XL AND WORKHORSE CUSTOM CHASSIS All Vortec 8100s built for these applications are equipped with a new returnless fuel injection system that eliminates fuel return lines between the engine and the gasoline tank. The new fuel system is also known as a demand system. Before model year 2004, the Vortec 8100’s sequential fuel injection (SFI) used a return line to manage fuel pressure by bleeding off excess fuel at the fuel rail and returning the excess to the tank. The new system eliminates the return lines and moves the fuel-pressure regulator from the fuel rail on the engine to the fuel tank. The fuel line from the tank now includes pulse dampeners, or a series of baffles, that manage fuel pulsing and limit noise. Because it delivers only the amount of fuel need by the injectors, and returns no fuel to the gas tank, the returnless system essentially eliminates heat transfer from the engine to tank. This reduces the amount of vapor generated in the tank, and captured by the evaporative emissions control system. Vortec 8100s built for the medium-duty Chevrolet Kodiak and GMC Topkick, as well as those built for marine and industrial applications, continue with fuel injection managed with return lines. LOW PERMEABILITY INTAKE MANIFOLD AND THROTTLE BODY GASKETS The Vortec 8100 has