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'90-96 Fuel Pump System

From 1983 Ford Bronco “That dirty old truck” — documented by Steve83.

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1983 Ford Bronco - '84-96 fullsize Ford truck EFI Fuel Flow IF THE IMAGE IS TOO SMALL, click it. [url=https://www.supermotors.net/registry/media/919580] https… 1983 Ford Bronco - '92-96 Bronco Fuel Pump & Level Wiring IF THE IMAGE IS TOO SMALL, click it. Tank connectors & pinouts are shown here: [url=https://www.supe… 1983 Ford Bronco - '92-96 (&'97 >8500GVWR) Gasoline F-series Dual Tank Switch IF THE IMAGE IS TOO SMALL, click it. '92-96 (& '97 >8500GVWR) Switch (Gas & Dies… 1983 Ford Bronco - FDM & Fuel Pressure IF THE IMAGE IS TOO SMALL, click it. Maximum fuel pressure is obtainable at WOT or the vacuum hose removed from the fue… 1983 Ford Bronco - This is the valve head from the Fuel Delivery Module (FDM) used in '90-04 F-series & Broncos (and some other Ford products). This one is th… 1983 Ford Bronco - Fuel Delivery Module IF THE IMAGE IS TOO SMALL, click it. The FDM is mounted to the tank plate (with tubes), and the level sender (with arm… 1983 Ford Bronco - Brazilian Bosch Fuel Delivery Module IF THE IMAGE IS TOO SMALL, click it. Short of spending ~$350 for a Ford hanger assembly (plate & FDM,… 1983 Ford Bronco - Factory fuel pump motor from a '95 5.8L Bronco 1983 Ford Bronco - V8 Fuel Pressure Port, Distributor, IAC, & Vacuum Tree (top R) [url=http://www.supermotors.net/registry/media/825934] http://www.supermotor… 1983 Ford Bronco - Fuel Pressure Gauge A Sears/Craftsman gauge costs $35-55, but many parts stores will loan/rent tools like this for a deposit. To check pres… 1983 Ford Bronco - The '93 frame-to-engine fuel line guide (under the driver's feet) uses riveted spring steel clips. The '95 uses snap-in plastic clips. 1983 Ford Bronco - Tank Delete IF THE IMAGE IS TOO SMALL, click it. To temporarily (or indefinitely) run any '90-96 dual-tank truck on 1 tank, it's necessary… 1983 Ford Bronco - Canister Purge Valve (CANP/CPRV) IF THE IMAGE IS TOO SMALL, click it. The port farther from the connector goes to the throttle body or mani… 1983 Ford Bronco - Carbon Canister (aka Charcoal Canister, Vapor Canister) Motorcraft CX741 Motorcraft W0133-1698805-MTR The activated charcoal inside the can… 1983 Ford Bronco - '87-95 4.9L MAP Vapor System with CANP IF THE IMAGE IS TOO SMALL, click it. The Evaporative Emission (EVAP) system prevents fuel vapor buil… 1983 Ford Bronco - '87-95 5.0L MAP Vapor System with CANP IF THE IMAGE IS TOO SMALL, click it. The Evaporative Emission (EVAP) system prevents fuel vapor buil… 1983 Ford Bronco - '87-95 5.8L MAP Vapor System with CANP IF THE IMAGE IS TOO SMALL, click it. The Evaporative Emission (EVAP) system prevents fuel vapor buil… 1983 Ford Bronco - Fuel Lines 95 Bronco (all EFI similar) IF THE IMAGE IS TOO SMALL, click it. Supply (pressure) lines are blue; return lines are gray. Same a… 1983 Ford Bronco - 93 F-series Fuel Lines 1983 Ford Bronco - '93-95 Lightning Evaporative Emissions 1983 Ford Bronco - Vapor Management Valve (VMV) replaces CANP on some '94-95 & all '96 trucks under 8500GVWR IF THE IMAGE IS TOO SMALL, click it. The EVAP Vap… 1983 Ford Bronco - V8 Vapor Management Valve (VMV, Ford F5TZ9C915A, Motorcraft CX1549) Connections (4.9L typical) IF THE IMAGE IS TOO SMALL, click it. When th… 1983 Ford Bronco - The larger surface-mounted C441 (WPT454) was used until '93; in '94, it switched to the smaller round inline connector. (Pump side: WPT330/… 1983 Ford Bronco - Fuel Pump Connector comparison [url=https://www.supermotors.net/registry/media/1126824] https://www.supermotors.net/getfile/1126824/thumbna… 1983 Ford Bronco - Early EFI Fuel Pump Connectors C441 (WPT-454) used through '93. '94-96 use the same wire colors, but a smaller round gray inline connector.… 1983 Ford Bronco - '87-96 Fuel Cap w/tether Ford F4TZ-9030-C ( MotorCraft FC920 ) or Motorad MGC817T. Also w/o tether Motorad MGC817 , Gates 31615 ACDelco 12F… 1983 Ford Bronco - '87-96 Filler Neck See also: [url=https://www.supermotors.net/registry/media/1150549] https://www.supermotors.net/getfile/1150549/thumbnail… 1983 Ford Bronco - The early-style fuel filler neck (EOTZ-9034-A) has a thin flexible plastic tube slid into a steel guide at the top of the steel pipe that c… 1983 Ford Bronco - Fuel Filler Necks Early trucks use a small corrugated plastic vent tube tucked into the top of the steel filler neck (EOTZ-9034-A) which ca… 1983 Ford Bronco - SOLD Fuel Filler Neck from '95 Bronco Fits all '80-96 fleetside aft-axle tank. Includes original mounting screws, & cap with tether & gromm… 1983 Ford Bronco - Filler Neck Comparison IF THE IMAGE IS TOO SMALL, click it. The steel is the same for gas trucks behind the axle SRW, but the rubber is dif… 1983 Ford Bronco - When a truck (or even just a tank) is abandoned with gas in it, the souring fuel (especially with ethanol) attacks the rubber fill hose ins… 1983 Ford Bronco - This truck's tanks were slow to fill, so I replaced the soft inner fill hoses with common 1" PEX from a hardware store that I formed w… 1983 Ford Bronco - Fuel Tank mounting & rollover valves IF THE IMAGE IS TOO SMALL, click it. Despite the details shown here, MOST of the straps I've found are… 1983 Ford Bronco - Bronco Tank Vapor Hose It takes slightly more than a foot to connect the steel vapor line on the frame to the rollover valve on the tank of… 1983 Ford Bronco - Vapor Valves The smaller valve ([url=https://www.amazon.com/dp/B008D33ZF8/]E7DZ9B593A ) uses a thicker (smaller I.D.) grommet (E3EC9B076AA… 1983 Ford Bronco - To remove the tank, begin by disconnecting the wiring and vent line, & removing most of the skid plate bolts. Most Broncos use bolts with a… 1983 Ford Bronco - Filler Neck Loosen the hose clamp at the tank & pull the outer filler neck off the tank. There is another hard plastic hose inside ('87-96)… 1983 Ford Bronco - Fittings With the tank lowered, the fuel lines can be disconnected using the appropriate tool. I prefer the small scissor (5/16" & 3/8… 1983 Ford Bronco - '93 Bronco Tank Details IF THE IMAGE IS TOO SMALL, click it. 1983 Ford Bronco - Recall check valve (1L3Z-9J274-AA) prevents fuel transfer between tanks (until it wears out, like this one has). [url=http://www.supermotor… 1983 Ford Bronco - Ford has been using hard nylon fuel tubing since the early 80s - I don't know why anyone is still using rubber, but I'm through with it. Mo… 1983 Ford Bronco - This is factory '85-91 fuel tubing, and it's what's inside the factory '92-up braided stainless. It's impervious to ethanol, so I actually… 1983 Ford Bronco - '86-91 Fuel Lines Garter Spring Safety Clips w/tethers 9mm E7AZ9A317A (E7AZ9A317AA) 12.5mm E7AZ9A317B (E7AZ9A317BA) [url=https://www.superm… 1983 Ford Bronco - Fuel Line Fittings The large scissor tool works best on garter springs; the small scissor works best on quick-disconnects. The only approve… 1983 Ford Bronco - '92-96 Fuel Lines (gas) are PTFE tubing inside SS braiding swaged to SS quick-connects with double-O-ring seals and colored rubber anti-rat… 1983 Ford Bronco - Wash & dry the top of the pump plate before disconnecting the lines or loosening the lock ring. Before attempting to disconnect the fuel li… 1983 Ford Bronco - Quick-Connect Cleaning IF THE IMAGE IS TOO SMALL, click it. Before putting a tool into a fuel line quick-connect, take a few minutes to bla… 1983 Ford Bronco - Quick-Disconnect Fittings IF THE IMAGE IS TOO SMALL, click it. The fittings at the '92-up fuel filter seem to be problematic for most peopl… 1983 Ford Bronco - This filter is for plastic hairpin fittings on older trucks - the correct filter for this truck has much longer nipples. Now that this stai… 1983 Ford Bronco - Fuel Bail Repair This stainless fuel quick-connect was used on Ford trucks from '92 to at least '97, and it can be troublesome. It requires… 1983 Ford Bronco - Clean Before opening the tank, buy a NEW O-ring and wash any dirt away from the pump plate. 1983 Ford Bronco - Lock Ring Cleaning also makes it much easier to turn the ring. 1983 Ford Bronco - Use a non-sparking tool to turn the ring, like a brass drift & dead-blow hammer. [url=https://www.supermotors.net/vehicles/registry/media/8… 1983 Ford Bronco - Unlock Ring A non-sparking drift is preferred, but with some water still on the tank, the chance of fire is low. Carefully tap each of the… 1983 Ford Bronco - FDM Removal Once the lock ring is removed, break the O-ring seal & lift the FDM from the tank. The reservoir will spill, and the pickup scr… 1983 Ford Bronco - Spoiled Gas Residue IF THE IMAGE IS TOO SMALL, click it. After ~5 years, gasoline sours and eventually turns to this foul tar-like residue,… 1983 Ford Bronco - SOLD F150 Rear Tank ('90-91) Actual size: 35x27x8" @ 31.5 lbs I cleaned most of the goo off the bottom. 1983 Ford Bronco - SOLD Bronco Gas Tank Large sender hole for '90-96 w/FDM, and some older. Suitable for upgrade from older dual-pump system, and to upgrade F… 1983 Ford Bronco - Reservoir Removal Remove the level sender upper mounting screw, press & hold the lock clip down, then lift the tube assembly from the reser… 1983 Ford Bronco - '87-96 Bronco Level Sender engineering number FOTF-9A299-AA 11/7/95-3 Fuel Tank Sending Unit Service PN: FOTZ-9A299-DB (MotorCraft PS22) Li… 1983 Ford Bronco - The level sender merely screws to the side of the FDM & its wire plugs onto the tank plate. Before reinstalling the FDM, I removed the EEC… 1983 Ford Bronco - FDM Wiring To temporarily or permanently convert a '90-up 2-tank truck to a single tank, read this caption: [url=http://www.supermotors.net… 1983 Ford Bronco - Pump Connection When replacing the FDM, the pump inside it, or just the reservoir head, the original wires CAN be connected to the new pump… 1983 Ford Bronco - Skid Plate & Pads If the pads are beyond re-use, I recommend camper shell mounting tape because it's a closed-cell foam intended for heavy… 1983 Ford Bronco - Tank Skidplate Dents IF THE IMAGE IS TOO SMALL, click it. The skidplate isn't very strong, so dents are very easy to pound or stomp out. 1983 Ford Bronco - Fuel Injector Types IF THE IMAGE IS TOO SMALL, click it. TSB 98-9-9 Fuel Injector Testing Information Publication Date: MAY 11, 1998 FORD:… 1983 Ford Bronco - Fuel Injector PNs & Specs IF THE IMAGE IS TOO SMALL, click it. See also: [url=https://www.supermotors.net/registry/media/724074_1] https://… 1983 Ford Bronco - Stuck Injectors can be freed by simply grounding the EEC wire (NOT the red wire) while the key is in RUN. After a few seconds (sometimes up… 1983 Ford Bronco - V8 Injector Swap IF THE IMAGE IS TOO SMALL, click it. Even with my size 9 hands, it's surprisingly possible to replace 5.0L & 5.8L injector… 1983 Ford Bronco - The fuel pressure regulator (Motorcraft '93-95 Lightning CM4764; '88-95 5.8L CM4760 ; 5.0L CM4766) is attached to the fuel rail downstream… 1983 Ford Bronco - Fuel Pump Warning Tag IF THE IMAGE IS TOO SMALL, click it. This was hung in new trucks to inform owners new to EFI that running the tank dr… 1983 Ford Bronco - Inertia Switch old style [url=https://www.supermotors.net/registry/media/862997] https://www.supermotors.net/getfile/862997/thumbnail/inert… 1983 Ford Bronco - Inertia Switches The old switch ('84~89) was installed on the firewall either just forward of the brake or clutch pedal or just R of the tr… 1983 Ford Bronco - Inertia Switches cracked open IF THE IMAGE IS TOO SMALL, click it. Typical locations for Bronco & F-series include: - firewall, between e-b… 1983 Ford Bronco - Inertia Switch new style [url=http://www.supermotors.net/registry/media/262703] http://www.supermotors.net/getfile/262703/thumbnail/inertia… 1983 Ford Bronco - '92-96 Inertia Switch Push in notch to reset. Remove the kick panel & pry the red button up through the notch in the housing to trip the sw… 1983 Ford Bronco - 92-93 Inertia Fuel Shutoff Switch Reset Indicator [url=http://www.supermotors.net/vehicles/registry/media/178340] http://www.supermotors.ne… 1983 Ford Bronco - Fuel Tank Capacity '92 & '95 IF THE IMAGE IS TOO SMALL, click it. For wheelbase, see this: [url=http://www.supermotors.net/registry/media/7… 1983 Ford Bronco - Fuel Additives These are what I use when I think my gas trucks need some fuel system maintenance. B12 is very strong & volatile, so I only… 1983 Ford Bronco - 96 F150 5.0L Front Tank Even though the truck ran on this tank when it was bought, it didn't run well, and would sometimes sputter or stall…