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FDM.jpg
7919 hits | 54.36 KB | Posted: 1/20/06

FDM & Fuel Pressure

For the 5.0L, 5.8L and 7.5L EFI engines, the in-tank mounted high pressure fu...
Fuel Lines 95 Bronco.jpg
3633 hits | 83.55 KB | Posted: 9/14/05

Fuel Lines 95 Bronco

Same as '90-96 single tank gas (& '97 over 8500GVWR)

The Fuel Tank Vapor...
FuelLevelWiring.JPG
294 hits | 78.84 KB | Posted: 7/19/09

Fuel Level Sender & Gauge Wiring for '92-96 Broncos

Sender Range: 160 (full) - 16 (empty) Ohms
A...
FuelLevelWiring.JPG
1634 hits | 72.66 KB | Posted: 9/30/07

COMBINE
http://www.supermotors.net/registry/media/744437
FuelPumpConnectors.JPG
33 hits | 66.51 KB | Posted: 11/6/09

The larger surface-mounted connector (WPT454) was used until '93; in '94, it switched to the smaller...
FPconnectors.JPG
246 hits | 103.38 KB | Posted: 7/19/09

Early EFI Fuel Pump Connectors used until '93.

Single-tank applications use the front tank colors...
FillerNeck93.JPG
28 hits | 75.44 KB | Posted: 11/14/09

'87-96 Filler Neck
Fuel Tank Bronco.jpg
3273 hits | 60.15 KB | Posted: 1/20/06

Fuel Tank mounting & rollover valves

All fuel tank vapor valves make use of a small orifice that...
VaporValves.JPG
23 hits | 76.45 KB | Posted: 11/14/09

Vapor Valves

The smaller valve uses a thicker grommet to fit in the same hole as the larger one.
Disconnect.JPG
2553 hits | 98.87 KB | Posted: 7/12/03

To remove the tank, begin by disconnecting the wiring and vent line, & removing most of the skid pla...
Filler.JPG
2016 hits | 84.1 KB | Posted: 7/12/03

Filler Neck
Loosen the hose clamp at the tank & pull the outer filler neck off the tank. There is ...
Fittings.JPG
2306 hits | 78.22 KB | Posted: 7/12/03

Fittings
With the tank lowered, the fuel lines can be disconnected using the appropriate tool. I p...
FuelLineFittings.jpg
2539 hits | 39.56 KB | Posted: 1/20/06

Fuel Line Fittings
The large scissor tool works best on garter springs; the small scissor works bes...
FuelPumpFitting.JPG
31 hits | 74.28 KB | Posted: 11/6/09

Push the fuel line HARD onto the pump fitting to releive the catches, & rotate it to break the O-rin...
FuelFittings.JPG
3583 hits | 34.94 KB | Posted: 3/20/07

Quick-Disconnect Fittings

The fittings at the fuel filter seem to be problematic for most people ...
Hose.JPG
2201 hits | 99.17 KB | Posted: 7/12/03

Clean
Before opening the tank, buy a NEW O-ring and wash any dirt away from the pump plate.
J 1.JPG
2045 hits | 94.38 KB | Posted: 7/12/03

Lock Ring
Cleaning also makes it much easier to turn the ring.
J 2.JPG
2093 hits | 75.24 KB | Posted: 7/12/03

Unlock Ring
A non-sparking drift is preferred, but with some water still on the tank, the chance of...
J 3.JPG
2268 hits | 98.4 KB | Posted: 7/12/03

FDM Removal
Once the lock ring is removed, break the O-ring seal & lift the FDM from the tank. The...
Module 1.JPG
2122 hits | 110.09 KB | Posted: 7/12/03

Reservoir Removal
Press the lock clip, then lift the tube assembly from the reservoir.
Module 2.JPG
2117 hits | 80.96 KB | Posted: 7/12/03

Level Sender PN
FOTF-9A299-AA
11/7/95-3
Fuel Tank Sending Unit
Service PN: FOTZ-9A299-DB (MotorC...
FuelLevelSenders.JPG
247 hits | 74.5 KB | Posted: 6/25/09

The level sender merely screws to the side of the FDM & its wire plugs onto the tank plate. Before ...
Module 3.JPG
2420 hits | 109.94 KB | Posted: 7/12/03

FDM Wiring
Module 4.JPG
1939 hits | 111.8 KB | Posted: 7/12/03

Pump Connection
Skid Plate.JPG
2488 hits | 116.35 KB | Posted: 7/12/03

Skid Plate & Pads

If the pads are beyond re-use, I recommend camper shell mounting tape because i...
FillerNeck 83.JPG
953 hits | 72.65 KB | Posted: 5/7/07

The early-style fuel filler neck has a thin flexible plastic tube slid into a steel guide at the top...
FillerNecks.JPG
1832 hits | 93.18 KB | Posted: 1/25/06

Fuel Filler Necks

Early trucks use a small corrugated plastic vent tube tucked into the top of th...
FuelInjectorsCutaway.jpg
1670 hits | 33.07 KB | Posted: 11/19/05

Fuel Injector Types

TSB 98-9-9 Fuel Injector Testing Information

Publication Date: MAY 11, 19...
Fuel Injector Specs.jpg
1108 hits | 40.7 KB | Posted: 10/26/05

Fuel Injector PNs & Specs
FPR.jpg
2264 hits | 41.58 KB | Posted: 1/22/06

The fuel pressure regulator is attached to the fuel rail downstream of the fuel injectors. It regula...
Inertia Switch 1.jpg
1884 hits | 39.51 KB | Posted: 2/17/05

Inertia Switch old style

[url=http://www.supermotors.net/registry/media/262703][img]http://www.su...
InertiaSwitches.jpg
2005 hits | 59.21 KB | Posted: 11/10/05

Inertia Switches

The old switch was installed on the firewall either just forward of the brake or...
InertiaSwitchesOpen.JPG
2661 hits | 47.71 KB | Posted: 11/12/05

Inertia Switches Open

[url=http://www.supermotors.net/registry/media/262703][img]http://www.super...
Inertia Switch 2.jpg
1700 hits | 22.35 KB | Posted: 2/17/05

Inertia Switch new style

[url=http://www.supermotors.net/registry/media/262703][img]http://www.su...
Inertia92-97.JPG
18 hits | 58.53 KB | Posted: 11/14/09

'92-96 Inertia Switch

Push in notch to reset.


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