Vortech 1999-2001 Ford 6.8L Super Duty User Manual
Page 9
P/N: 8N020-100
©2002 Vortech Engineering, LLC
All Rights Reserved, Intl. Copr. Secured
28MAR02 V1.0
(99-01SDPwrCoolr(8N020-100V1.0)
3
3.
IN-TANK FUEL PUMP REPLACEMENT
NOTE: The following steps are best per-
formed with the gas tank with the
least amount of fuel in it as possible.
A. Support the gas tank with a jack and remove the
screws securing the two gas tank straps.
B. Slightly lower the gas tank and disconnect the
top two vents on the gas tank, front and rear.
C. Disconnect the fuel pump/sender wiring har-
ness located in the frame rail and the fuel fill and
overflow lines.
D. Disconnect the fuel feed and return lines using
a springlock tool.
E. Completely lower the gas tank to the ground.
F. Unscrew the outer ring securing the fuel lines
and remove the cover.
G. Depress the two clips securing the plastic fuel
pump enclosure and slide it out of the tank, the
fuel sender float is attached to the fuel pump
enclosure and must be handled with care. Be
careful not to damage the filter.
H. Cut the two fuel pump power wires about 1” from
the fuel pump electrical connector. Noting the
corresponding (+) and (-) connections, splice
the supplied wiring harness into place using two
solderless connectors.
I. Remove the three screws securing the fuel
pump enclosure’s cover using a 3/16” nut driver
and remove the cover. Cut three equally spaced
1/2" long slits in the perimeter of the cover’s fuel
pump locating cylinder (see
Fig. 3-a). This al-
lows the larger O.D. pump to fit in the cover.
Some material may need to be removed from
the I.D. of the pump locating cylinder for proper
pump fit.
J. Remove the stock fuel pump from its enclosure.
Separate the rubber pump support and filter
from the pump and install both onto the supplied
pump.
K. Reassemble the new fuel pump assembly and
canister with cap. Install the supplied 1/8” spac-
ers beneath the pump outlet manifold and the
canister cap. (See
Fig. 3-b.) Using the outlet
manifold mount holes as a template, drill two 1/
16” pilot holes into the enclosure cover. Secure
the outlet manifold to the cap using the two self
tapping #6 screws. Reinstall the fuel tank as-
sembly and reattach the electrical connections.
L. Reinstall the canister assembly into the fuel tank
and screw on the outer ring to secure it.
M. Reinstall the gas tank and reconnect all the fuel
lines and electrical connections.
CUT THREE 1/2"
LONG SLITS HERE
PUMP CANISTER
BYPASS
TUBE
SUPPLIED 1/8"
SPACERS
#6 SCREWS
PLASTIC FUEL
PUMP OUTLET
MANIFOLD
FUEL OUTLET
HOSE
FUEL PUMP OUTLET
Fig. 3-a
Fig. 3-b