Fuel Tank & Fuel Lines Ford Cutaway E350

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Fuel Tank and Lines - 4.6L, 5.4L and 6.8L

The fuel system consists of

1. the fuel tank. The midship fuel tank is between the frame side rails on the left hand side. The aft of axle fuel tank is mounted between the side rails.
2. a fuel tank filler pipe which contains a restrictor plate to permit only unleaded fuel to be pumped into the fuel tank.
3. a quarter-turn fuel tank filler cap.
4. a fuel filter providing filtration to protect the fuel injectors.
5. fuel tubes.
6. a fuel pump and sender assembly which provides pressurized fuel to the engine and a signal to indicate fuel level to the instrument cluster, and contains: a serviceable fuel sender. an inlet filter. a check valve that maintains system pressure after the pump is shut off.

The fuel pump is controlled by the fuel pump powertrain control module relay. Electrical power to the fuel pump is provided through the inertia fuel shutoff (IFS) switch.

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Fuel Tank and Lines - 6.0L Diesel

The diesel fuel system consists of

1. the fuel tank. The midship fuel tank is mounted to the LH frame side rail. The aft-of-axle fuel tank is mounted between the side rails.
2. a fuel tank filler pipe without a restrictor plate.
3. a threaded fuel tank filler cap.
4. the fuel conditioning module. contains the primary fuel filter and water separator. has the fuel pump mounted in the top. has a internally mounted fuel warmer (not serviced separately). contains a pressure relief valve for overpressure protection in the event of restricted flow.
5. fuel tubes.

The fuel pump is controlled by the fuel pump powertrain control module (PCM) relay. Electrical power to the fuel pump is provided through the inertia switch (IFS switch). The fuel recirculation/filter unit assists in preventing the fuel from gelling in the lines during cold weather operations.

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Fuel Tank and Lines

For additional information, see INTRODUCTION - GASOLINE and INTRODUCTION -- 6.0L DIESEL articles.

Fuel Conditioning Module - 6.0L Diesel

Note. Fuel Conditioning Module contains the primary fuel filter and water separator.

Special Tool(s)

SPECIAL TOOL Fuel Line Disconnect Tool 310-S039 (T90T-9550-S)

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350/2004-2007/remont/hoistjack/#jacking-lifting) .
2. Disconnect both battery ground cables. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) .
3. Open the fuel/water separator drain valve to release the fuel pressure.
4. Disconnect the fuel conditioning module electrical connectors.
5. Remove the fuel hoses retaining clips. Using the special tool, disconnect the four fuel hoses.
6. Disconnect the wiring push pin. Remove the mounting bolts and the fuel conditioning module.
7. To install, reverse the removal procedure.

SPECIAL TOOL(S) Disconnect Tool, Spring Lock Coupling 310-S039 (T90T-9550-5) High-Lift Transmission Jack 014-00942 or equivalent

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Removal and Installation

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350/2004-2007/remont/hoistjack/#jacking-lifting) .
2. Release the fuel pressure. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/cutaway-e350/2004-2007/remont/fuel-system/#fuel-system-general-information) .
3. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) .
4. Drain the fuel tank. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/cutaway-e350/2004-2007/remont/fuel-system/#fuel-system-general-information) .
5. Disconnect the fuel pump/fuel sender electrical connector.
6. Disconnect the fuel tank filler pipe hose.
7. Disconnect the evaporative emissions (EVAP) tube connector.
8. Position the jack under the fuel tank.
9. Remove the nut and the front fuel tank support strap.
10. Remove the nut and the rear fuel tank support strap.
11. Partially lower the fuel tank.
12. Disconnect the fuel tube spring lock coupling. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/cutaway-e350/2004-2007/remont/fuel-system/#fuel-system-general-information) .
13. Disconnect the fuel tank vent tube connector.
14. Lower the fuel tank.
15. To install, reverse the removal procedure.

SPECIAL TOOLS Disconnect Tool, Spring Lock Coupling 310-S039 (T90T-9550-5) High-Lift Transmission Jack 014-00942 or equivalent

Note. The 55 gallon aft-of-axle fuel tank is shown; the 37 gallon aft-of-axle fuel tank is similar. All vehicles

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350/2004-2007/remont/hoistjack/#jacking-lifting) .
2. Release the fuel pressure. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/cutaway-e350/2004-2007/remont/fuel-system/#fuel-system-general-information) .
3. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) .
4. Drain the fuel tank. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/cutaway-e350/2004-2007/remont/fuel-system/#fuel-system-general-information) .
5. Disconnect the fuel tank filler pipe and the filler vent tube from the fuel tank.
6. Position the jack under the fuel tank.
7. Remove the bolts.
8. Remove the nuts.
9. Remove the fuel tank support straps.
10. Partially lower the fuel tank.
11. Disconnect the evaporative emission (EVAP) tube(s) from the fuel vapor/grade vent valve.
12. Disconnect the fuel pressure electrical connector.
13. Disconnect the EVAP tube from the fuel pump.
14. Disconnect the fuel tube spring lock coupling. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/cutaway-e350/2004-2007/remont/fuel-system/#fuel-system-general-information) .
15. Disconnect the fuel pump and fuel tank sending unit electrical connector.
16. Lower the fuel tank.
17. To install, reverse the removal procedure.

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1. Remove the fuel tank. For additional information, refer to «FUEL TANK - MIDSHIP»(/ford/cutaway-e350/2004-2007/remont/fuel-system/#fuel-tank-fuel-lines) or «FUEL TANK - AFT-OF-AXLE»(/ford/cutaway-e350/2004-2007/remont/fuel-system/#fuel-tank-fuel-lines) .
2. Place the fuel tank on a suitable work surface.
3. Disconnect the evaporative emissions (EVAP) tube.
4. Remove the bolts and the fuel pump and sender. Discard the fuel pump O-ring seal.
5. To install, reverse the removal procedure. Install a new fuel pump O-ring seal.

Scheme 151

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350/2004-2007/remont/hoistjack/#jacking-lifting) .
2. Release the fuel pressure. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/cutaway-e350/2004-2007/remont/fuel-system/#fuel-system-general-information) .
3. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) .
4. Disconnect the fuel tube spring lock couplings from the fuel filter. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/cutaway-e350/2004-2007/remont/fuel-system/#fuel-system-general-information) .
5. Slide the fuel filter out of the bracket.
6. To install, reverse the removal procedure.

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1. Detach the coolant hoses from the air cleaner outlet pipe.
2. Loosen the clamps and remove the air cleaner outlet pipe.
3. Loosen the clamp on the charged air cooler duct at the intake manifold adapter.
4. Loosen the clamp on the charged air cooler duct at the charged air cooler.
5. Remove and position the charged air cooler duct aside.
6. Remove the secondary fuel filter cap by turning the cap counterclockwise and remove the secondary fuel filter. Discard the secondary fuel filter. Carefully clean the mating surfaces.
7. To install, reverse the removal procedure.

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1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) .
2. Remove the RH cowl side trim panel.
3. Disconnect the inertia fuel shutoff (IFS) switch electrical connector. Remove the bolts and IFS switch.
4. To install, reverse the removal procedure.

Note. Fuel Conditioning Module contains the primary fuel filter and water separator.

Material

MATERIAL SPECIFICATION

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1. Remove the fuel filter cover and drain the fuel from the housing.
2. Remove and discard the fuel filter and O-ring seal.
3. Remove the bolts and the fuel pump. Remove and discard the O-ring seals.
4. Remove the bolts and the pressure relief valve. Remove and discard the O-ring seals.
5. Remove the bolts and the fuel conditioning mounting bracket.

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1. Install the fuel conditioning module mounting bracket and bolts.
2. Install new O-ring seals on the fuel pump and lubricate with clean engine oil.
3. Install the fuel pump and mounting bolts.
4. Install new O-ring seals on the relief valve cover and apply clean engine oil.
5. Install the pressure relief valve and bolts.
6. Install a new O-ring seal and fuel filter on the fuel filter cover. Lubricate the O-ring seal with clean engine oil.
7. Install the fuel filter cover. Tighten the fuel filter cover to 13 Nm (10 lb-ft). Rotate the fuel filter cover until the electrical connectors line up.

See also:
• INTRODUCTION - GASOLINE
• INTRODUCTION -- 6.0L DIESEL
• JACKING & LIFTING
• BATTERY, MOUNTING AND CABLES
• FUEL SYSTEM-GENERAL INFORMATION
• FUEL TANK - MIDSHIP