Fuel Line Replacement
CAUTIONFuel lines may still contain fuel. Use caution when disconnecting.
1. Refer to Figure 3. Remove the three bolts holding the fuel filter bracket to the frame. Retain one bolt for subsequent use.
2. Disconnect "Push Connect" fitting at the high pressure pump outlet nipple by removing hairpin clip and twisting the line while pulling on it.
3. Using a 16 mm wrench for the fitting and a 14 mm wrench (on the boss of the fuel pump) for backup, unscrew outlet nipple from the front of the high pressure fuel pump. Discard nipple and copper sealing washer.
4. Install new copper washer (E6TZ-9374-A) on the new fuel pump nipple (E6TZ-9416-A). Screw this new nipple into the pump. Torque to 12-16 N.m (9-12 lbs.ft.), while keeping a 14 mm wrench (on the boss of the fuel pump) for backup.
5. Select the appropriate new fuel line as per "Parts Ordering Information".
6. Remove red shipping plug on fuel pump outlet connector of the fuel line if present. Leave white shipping plug on for protection. Install the end of the fuel line with the small bell-shaped connector to the new fuel pump outlet nipple. Push on to nipple until distinct click is heard or felt. Pull on line to test for and confirm retention. Engage the retainer clip to line and nipple by firmly pushing down on the clip. (Reference Figure 7).
NOTE:
If fuel line removal is required use tool T90T-9550-B to release connector.
7. Route fuel line forward inside frame rail, following routing of fuel return line. Install clip N800558-S100 to retain fuel lines, by bolting to lower front bolt hole in frame, that was previously used for the fuel filter bracket. Refer to Figures 1, 2, and 5. Use bolt from Step 1. and nut N620480-S100 Torque to 8-12 N.m (6-9 lbs. ft.) Ensure fuel line is pressed against frame rail web to clear automatic transmission shift linkage.
8. Disconnect the fuel supply line at the engine fuel rail as follows:
^ lift the tethered retaining clip off the coupling connection. Move it aside, leaving it hanging by its tether (Refer Figure 6).
^ disconnect the fuel line spring lock coupling, using the proper special service tool. Refer to Figure 4.
9. 5.0L or 4.9L engines equipped vehicles. Remove the complete fuel supply line, filter and jumper fuel line as an assembly. Mutilate and scrap.
10. 5.8L or 7.5L engine equipped vehicles. Use a pair of diagonal side cutters to cut both ends of the fuel supply line flush with the foil insulation wrapping. This leaves the wrapped section of the original supply line in place, which is not to be disturbed. Use caution to avoid damaging fuel return line. Mutilate and scrap the ends of fuel lines, fuel filter and bracket and "jumper" fuel line.
11. Remove white shipping cap and connect fuel line to engine fuel rail. Refer to Figure 4. Install retainer clip previously removed in Step 8. Refer to Figure 6.
12. (5.0L or 4.9L) Strap new fuel line to existing fuel return line using tie straps 95874-S at 8" (20 cm) intervals. Refer to Figures 2 and 5. Cut off excess tie strap length.
13. (5.8L or 7.5L) Strap new fuel line to existing fuel line insulation bundle as shown in Figure 1. Locate tie straps 95874-S at 8" (20 cm) intervals. Ensure heat shield is installed as shown in Figure 1. Use additional strap to secure fuel line to shield. Cut off excess tie strap length. Slight excess fuel line length is allowed to form a "hump" at the upper end of the fuel line near the engine.
14. Lower vehicle.
15. Reconnect battery ground cable.
16. Cycle ignition key to "ON" position 5 times at 2 second intervals to prime the fuel system. Inspect reservoir, pump nipple and fuel line connections for leaks (correct as required).
17. Start engine and reinspect the fuel system for leaks. (Correct as required).
18. (4 X 4 only) Reinstall fuel reservoir shield. Torque attaching bolts to 16-20 N.m. (12-15 lbs. ft.)
19. (4 x 4 only) Reinstall driveshaft, if removed, making sure markings on rear slip yoke and transfer casing yoke line up so as to maintain driveshaft balance.
20. Mutilate and scrap all removed parts.