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Cut-out Measurements for Fuel Pump/Sender Replacement Links
Source: by miesk5 at broncolinks.com
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"...Pre 90- 2" tank hole for a low pressure in-tank pump (feeds the high pressure pump) plus a high pressure frame rail pump; Post 90- 3-5/8" tank hole for a single high pressure in-tank pump, no other pumps in the system..."
Source: by Dustin S (Dustball, Mellow Yellow, Mr. Laser Boy) at FSB
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Auxiliary Fuel Tank Fabrication in an 86
Source: by chemfrk (Blue) at SuperMotors.net
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Connector pic in a 96
Source: by PWMTN (Paul) at FSB
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Connector; "...The larger surface-mounted connector (WPT454) was used until '93; in '94, it switched to the smaller round inline connector. (Pump side: WPT330/WPT335; Truck side: WPT111/WPT807/WPT81..."
Source: by Steve83 (Steve, That dirty old truck) at SuperMotors.net
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Fabrication & Installation, 44 gallon Midship in a 79 CC
Source: by Trent (Picador, a Four Door 79, InfoFord) at fourdoorbronco.com
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Fabrication & Installation, 53 gallon in an 89 Centurion (must register to view pics)
Source: by Traveler (Centurion) at fourdoorbronco.com
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Fill & Vent Tube pic in 87-96 at Tank
Source: by Steve83 (Steve, That dirty old truck) at SuperMotors.net
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Fill & Vent Tube pic in a 96
Source: by nsasanas (Black Iron Horse) at SuperMotors.net
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Fill & Vent Tube pics in pre 87 & 87 & up; "...Early trucks use a small corrugated plastic vent tube tucked into the top of the steel filler neck , but it often kinks & blocks fuel from entering the tank easily. Later trucks use a heavy plastic filler hose inside the steel vent neck, which allows MUCH easier filling.The necks are interchangeable, so it's a good upgrade for an old truck, especially if filling is becoming a problem. It also allows the use of a more modern gas cap..."
Source: by Steve83 (Steve, That dirty old truck) at SuperMotors.net
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Fill & Vent Tube Removal; "...there should be three hose clamps. One at the top near the filler door, one about 8 inches down from there which wraps around the hose and another support bracket attached to the body, and a third down by the tank. You will probably need to cut it off which is not a big deal because you are not reusing it anyway..." read more
Source: by digitalbill (Bill Crozier) at FSB
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Fill Pipe Depiction & Parts Break-Out Diagram
Source: by Steve83 (Steve, That dirty old truck) at SuperMotors.net
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Fuel Level Sender, disconnect the plug & jump the terminals, it should peg the gauge at full
Source: by Billz4x4z at Ford Bronco Zone Forums
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Hanger Fabrication Info & pic & Painting in a 79
Source: by nunrush at SuperMotors.net
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Hard to Re-Fuel, Gas Station Pump Shuts-Off; "...There is a plastic vent tube inside the filler neck that often gets kinked..."
Source: by justshootme84 (Randy Z, Casual Mudder) at Ford Bronco Zone Forums
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Harness Repair in an 86
Source: by Sixlitre (Malcolm H, Eddie Bauer) at SuperMotors.net
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Harness Repair in an 86
Source: by Sixlitre (Malcolm H, Eddie Bauer) at FSB
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Installation in an 83 (he did an EFI Swap)
Source: by Michael C (collinsperformance, The Money Monster) at SuperMotors.net
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Installation in an 86
Source: by Sixlitre (Malcolm H, Eddie Bauer) at SuperMotors.net
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Installation in an 86
Source: by Sixlitre (Malcolm H, Eddie Bauer) at FSB
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Installation in an 87
Source: by Spectre (Vic S, Wife's Bronco) at FSB
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Installation Info, 19 gallon Polyethylene in a 78
Source: by 78broncoboy at FSB
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Installation pics in an 87
Source: by Spectre (Vic S, Wife's Bronco) at SuperMotors.net
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Installation pics, 33 gallon in a 79
Source: by FordTruckBroncoMan (Big Red, FordTruckMan) at SuperMotors.net
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Installation, JBG Polyethylene (MTS mfgr) in an 86
Source: by Fireguy50 (Ryan M) at FSB
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Installation, JBG Polyethylene (MTS mfgr) Problems in a 91; "...i bought one of those plastic ones from JBG... it doesnt fit... the skid plate isnt even tightened all the way up (its dangling by the 2.5" long bolts..the tank is too obviously) and the top of the tank was hitting the floor..."
Source: by DcSkater602 (Steve) at FSB
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Installation, JC Whitney Problems in a 90; "... had the same exact problems with my plastic tank. I bought mine from JC Whitney. It didn't fit right and after fiddling with and unscrewing the upper harness limiting straps until they were maxed out it fit and then while filling the tank I discovered that there was a crack along the side of the tank about half way up. Hell of a thing to discover when you just put close to 15 gallons of gas in your tank and to have it start gushing out instantly. Luckily my garage wasn't far from the gas station so I drove it home spilling gas everywhere. Took it back and siphoned the fuel out, called JC Whitney and they're shipping me a new one free of charge even though they claimed to have never had this complaint before. I think I might sell it though and just buy a new metal one like you had. That or figure out a way to make spacers to make up for the extra height. I guess they had to make the tank larger in order to make up for all of that extra wall thickness, but this is a real headache..."
Source: by 5billiondead at FSB
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Installation, JEG's fuel system Info & pics, 15 Gallon in an 84
Source: by Richard C (Bigric, Money Pit) at SuperMotors.net
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Installation, Northwest Metal 45 gallon in an 87
Source: by Chris P (Maximum) at abysmal.com
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Installation, Polyethylene; "...I absolutely hated the poly tank I had to put in the '75; especially those scraps of bent GARBAGE that hold the sender plate in..."
Source: by Steve83 (Steve, That dirty old truck) at SuperMotors.net
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Mods in a 78
Source: by Quint C (Quints Bronco Project, (04 F-150 Supercrew drivetrain) at comcast.net/~qcrispin
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Overview & Parts Break-Out & System Diagrams in a 95; "...Basically how the system works is the valve you see on top of the tank is the evaporative emission valve (9B593) mounted on the top of the fuel tank (9002) is used to control the flow of fuel vapor entering the fuel tank vapor delivery line which conducts vapor forward to the evaporative emissions canister (EVAP canister) (9D653) in normal circumstances. If, due to extreme conditions, excessive pressure is generated inside the tank, the purge port opens up, allowing fuel vapor to escape to the atmosphere, and stabilizes pressure inside the fuel tank. The evaporative emission valve has a head valve which prevents the fuel tank from overfilling during refueling operation. The evaporative emission valve also has a spring supported float assembly, which prevents liquid fuel from entering the vapor delivery line during severe handling, steep grades or in the event of vehicle rollover. Now when the engine is off the pressure from tank will open the valve and let vapors go into the vapor lines to the carbon canister in the front. Then when you start the vehicle the canister purge valve will open and draw the vapors from the canister back into the engine to be re burned. Now the canister is sealed and should not leak but it does not really hold pressure. The valve in the tank should close when the pressure equalizes in the tank. and the carbon in the canister absorbs the vapors and holds them until the engine is started. Also check the canister purge solenoid make sure it click good if you supply power on the red wire just to make sure it isn't stuck and you can unhook the hose and pull a vacuum on not and make sure it is not leaking..."
Source: by Chuck at justanswer.com
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Parts & Overhaul pics in a 90
Source: by BlueBeast (The Beast), JP N) at SuperMotors.net
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Parts Break-Out Diagram for Carbureted Engines without Nomenclature
Source: by Steve83 (Steve, That dirty old truck) at SuperMotors.net
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Parts Break-Out Diagram in a 78 without Nomenclature
Source: by Indybronco (Lula Mae) at SuperMotors.net
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Parts Break-Out Diagram in a 78 without Nomenclature
Source: by broncohq.com
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Polyethylene 19 Gallon pic in a 78
Source: by 78bronco460 (Phat Ho, Jim H) at SuperMotors.net
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Polyurethane Differences info in 78-79
Source: by Kevin M (Project Double Agent) at okcnetworks.com
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Polyurethane Info in an 86; miesk5 Note; K BAR S is out-of-business
Source: by Andy B at 2bbnorthwest.org via web.archive
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Raised Info & pics in a 79
Source: by nunrush at SuperMotors.net
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Raised Info & pics in a 91
Source: by jtg (Jackson) at uc4x4.com
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Raised Info & pics in an 80
Source: by Tony B at SuperMotors.net
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Raised Installation in a 95
Source: by Rafael E (Bronkzilla, stressed) at SuperMotors.net
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Raised Installation in a 95
Source: by Rafael E (Bronkzilla, stressed) at FSB
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Raised Installation in an 85
Source: by Tim O (RED WAGON, redwagon) at SuperMotors.net
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Raised Installation in an 86
Source: by Damager (Da Bonco) at SuperMotors.net
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Raised pics in a 91
Source: by jtg (Jackson) at SuperMotors.net
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Raised pics in an 84
Source: by sceep (Nate) at Pirate4x4.Com
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Rebuild & cross member mods, 16 gallon in an 88
Source: by Reptillikus (Project 4D2, Kevin W) at bucknakedoffroad.com
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Recall, Cracked Fuel Vapor Hoses on 1986 through 1988 Model Ranger, F-Series & Broncos Equipped With California 2.3L and 4.9L Engines, Emissions 91E04
Source: by Ford via Chilton
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Recall, Cracked Fuel Vapor Hoses on Certain 1986 & 1987-Model F-Series & Bronco Trucks, Emissions 90E92, Equipped with California 5.0L Engines; having calibrations 6-54Q-R00 & 6-54S-R00 (1986-Model) 7-54R-R05/R11 & 7-54S-R05/R11 (1987-Model)
Source: by Ford via Chilton
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Relocated pics in a 79 F 150 4x4
Source: by Goose (Ol' Muddy) at SuperMotors.net
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Removal & Repairs in an 83 (he did an EFI Swap)
Source: by Steve83 (Steve, That dirty old truck) at SuperMotors.net
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Selector Switch Testing in a 90 F 150 w/Dual Tanks & Pumps
Source: by Ford via subford (Bill K) at fte
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Size Differences, 25 vs. 35 gallon pic in a 78
Source: by Jason R (baby ruth) at SuperMotors.net
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Skid Plate & Mods & pics in a 90
Source: by Alan T (GearHead) at SuperMotors.net
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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 loads with slight movement in an automotive environment..."
Source: by Steve83 (Steve, That dirty old truck) at SuperMotors.net
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Skid Plate (boxed) Fabrication in an 88
Source: by Masterphil (Phillip H, Double D) at FSB
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Skid Plate (boxed) pics in an 88
Source: by Masterphil (Phillip H, Double D) at SuperMotors.net
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Skid Plate Fabrication & Installation in a 78 (pics are gone)
Source: by OX1 (OX, Jim, James O) at FSB
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Skid Plate Fabrication & Installation in a 95
Source: by Shadofax (TheJuice, The Juice, Mark Z) at SuperMotors.net
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Skid Plate Fabrication & Installation in an 81 (pics are gone)
Source: by Larry S (The Bronc, Larston, Lars915, Lars) at stubig4x4.com via web.archive.org
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Skid Plate Fabrication & Installation in an 89
Source: by Gargoyle at FSB
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Skid Plate Fabrication Info & pics in a 90
Source: by Chris S (Swat, Carcass, Blown, CLYDE) at FSB
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Skid Plate Fabrication pics in a 96
Source: by Goose (Ol' Muddy) at SuperMotors.net
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Skid Plate Info & pics in an 87
Source: by Nathan G (thenag, Bruiser Woods) at SuperMotors.net
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Skid Plate Installation in a 91
Source: by ChuckVA (Chuck, Da Bronco) at SuperMotors.net
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Skid Plate Installation in an 80
Source: by Tony B at SuperMotors.net
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Skid Plate Parts Break-Out Diagram for Carbureted Engines
Source: by Steve83 (Steve, That dirty old truck) at SuperMotors.net
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Skid Plate pics in a 78
Source: by Erik M (The Anchor) at SuperMotors.net
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Skid Plate pics in a 79
Source: by Steven R (gobucs1, Rust Bucket, Da BronK) at SuperMotors.net
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Skid Plate pics in a 90
Source: by Chris S (Swat, Carcass, Blown, CLYDE) at SuperMotors.net
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Skid Plate pics in a 90
Source: by Darren W (Black Goliath) at SuperMotors.net
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Skid Plate pics in an 81
Source: by Larry S (The Bronc, Larston, Lars915, Lars) at SuperMotors.net
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Strap Replacement pics in an 88 C-350 (Centurion Conversions)
Source: by AudraJean (Audra, Audra C, Redçmptiôn, Lochness Monster, Audra D) at SuperMotors.net
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Sump & Electric Pump Info & pics in a 78
Source: by Matt I (Red, freak) at Ford Bronco Zone Forums
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Sump & Electric Pump pics in a 78
Source: by Matt I (Red, freak) at SuperMotors.net
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Switch, F-series Tank Wwitch or Bronco Rear Window Glass Switch. In-Dash in 92-96; "...It's becoming more common for the F-series tank switch or Bronco rear window switch to break loose from the back of the cluster bezel, and repairing the screw holes on the bezel is nearly impossible. This makes more sense to me, anyay - I don't know why Ford didn't do this to begin with, and the same for the diesel warning lights, and the ESOF switch on the other side of the column...."
Source: by Steve83 (Steve, That dirty old truck) at SuperMotors.net
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V REST on 78/79 & early 80s is a Vacuum Restictor/Delay Valve, it delays vacuum for a certain amount of time. On most engines a vacuum line from the carburetor base runs to a T & then to V REST to the distributor; READ MORE
Source: by miesk5 at FSB
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V REST on earlier years such as SEABRONC's 83 is a Vacuum Restictor/delay valve, it delays vacuum for a certain amount of time
Source: by miesk5 at Ford Bronco Zone Forums
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V REST Vapor Valve (Roll-Over) Valve on later year Depictions & Location Diagrams in 5.0, 5.8, 7.5, & 4.9; "...All fuel tank vapor valves make use of a small orifice that tends to allow only vapor and not fuel to pass into the line running forward to the vapor storage canister. This assembly mounts directly to the fuel tank using a rubber seal. Fuel vapors trapped in the sealed fuel tank are vented through the orificed vapor valve assembly in the top of the tank. The vapors leave the valve assembly through a single vapor line and continue to the carbon canister for storage, until they are purged to the engine. The vapor valve assembly mounted on the top of the fuel tank is used to control the flow of fuel vapor entering the fuel tank vapor delivery line which conducts vapor forward to the canister in normal circumstances. If due to extreme conditions, excessive pressure is generated inside the tank, the purge port opens up, allowing fuel vapor to escape to the atmosphere, and stabilizes pressure inside the tank. The valve assembly has a head valve which prevents the fuel tank from overfilling during refueling operation. The valve assembly also has a spring supported float assembly, which prevents liquid fuel from entering the vapor delivery line during severe handling, steep grades or in the event of vehicle rollover. The fuel fill cap is sealed and includes a built-in pressure-vacuum relief valve. Fuel system vacuum relief is provided after 3.5 kPa (0.50 psi) and pressure relief after 11.0 kPa (1.6 psi). Under normal operating conditions, the fill cap operates as a check valve, allowing air to enter the tank as fuel is used, while preventing vapors from escaping the tank through the cap..."
Source: by Steve83 (Steve, That dirty old truck) at SuperMotors.net
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V REST Vapor Valve (Roll-Over) Valve Overview & Evap System Parts Break-Out & System Diagrams in a 95; "...Basically how the system works is the valve you see on top of the tank is the evaporative emission valve (9B593) mounted on the top of the fuel tank (9002) is used to control the flow of fuel vapor entering the fuel tank vapor delivery line which conducts vapor forward to the evaporative emissions canister (EVAP canister) (9D653) in normal circumstances. If, due to extreme conditions, excessive pressure is generated inside the tank, the purge port opens up, allowing fuel vapor to escape to the atmosphere, and stabilizes pressure inside the fuel tank. The evaporative emission valve has a head valve which prevents the fuel tank from overfilling during refueling operation. The evaporative emission valve also has a spring supported float assembly, which prevents liquid fuel from entering the vapor delivery line during severe handling, steep grades or in the event of vehicle rollover. Now when the engine is off the pressure from tank will open the valve and let vapors go into the vapor lines to the carbon canister in the front. Then when you start the vehicle the canister purge valve will open and draw the vapors from the canister back into the engine to be re burned. Now the canister is sealed and should not leak but it does not really hold pressure. The valve in the tank should close when the pressure equalizes in the tank. and the carbon in the canister absorbs the vapors and holds them until the engine is started. Also check the canister purge solenoid make sure it click good if you supply power on the red wire just to make sure it isn't stuck and you can unhook the hose and pull a vacuum on not and make sure it is not leaking..."
Source: by Chuck at justanswer.com
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V REST Vapor Valve on later year pics in 5.0, 5.8, & 4.9...The smaller valve uses a thicker grommet to fit in the same hole as the larger one..."
Source: by Steve83 (Steve, That dirty old truck) at SuperMotors.net
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V REST Vapor Valve pic in a 95 5.0
Source: by BigMatt302 (bigmatt) at FSB
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V REST Vapor Valve pic in a 95 5.0
Source: by bigmatt (BigMatt302) at SuperMotors.net
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V REST Vapor Valve pic in a 96
Source: by PWMTN (Paul) at FSB
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Vacuum Line Routing Diagram in a 83 351W
Source: by Seabronc (Rosie, Fred W) at SuperMotors.net
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Vapor Line Routing Diagram in a 95 (Same as 90-96); from Vapor Cannister to Fuel Tank; "...The system begins in the fuel tank where one or more valves are used to vent vapor pressure, but also to exclude liquid from the vapor system due to overfilling, slosh, or rollover. There may also be a pressure sensor to monitor the system's operation & effectiveness, and/or a vent valve (CANV solenoid, or built into the cap) to allow fresh air [b]into[/b] the fuel tank or vapor system. As vapor exits the tank, it flows thru a tube to a canister containing carbon (activated charcoal), which absorbs the fuel vapor, but allows air to pass. Depending on the size of the fuel tank, there may be several canisters, or a larger canister. Older canisters are vented, but they're known to collect water, so most modern canisters are sealed. Another tube leads from the canister toward the engine's intake, but it may contain a regulator valve (CANP solenoid, or VMV). Being virtually a zero-maintenance system, most faults are simple valve failures, hose leaks, or mechanical damage (collision, road debris, etc.). Faults in the evaporative systems are usually detected by the use of a special machine which pumps a non-toxic non-flammable high-visibility smoke into the vapor lines to make leaks evident. But a common source of evaporative codes on '97-04 vehicles is the operator not securing the fuel filler cap. Earlier vehicles didn't detect this, and later vehicles are designed to exclude this from turning on the CEL..."
Source: by Steve83 (Steve, That dirty old truck) at SuperMotors.net
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Vent & Fill Tube pic in 87-96
Source: by Steve83 (Steve, That dirty old truck) at SuperMotors.net
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Vent & Fill Tube pics in pre 87 & 87 & up; "...Early trucks use a small corrugated plastic vent tube tucked into the top of the steel filler neck , but it often kinks & blocks fuel from entering the tank easily. Later trucks use a heavy plastic filler hose inside the steel vent neck, which allows MUCH easier filling.The necks are interchangeable, so it's a good upgrade for an old truck, especially if filling is becoming a problem. It also allows the use of a more modern gas cap..."
Source: by Steve83 (Steve, That dirty old truck) at SuperMotors.net
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Vent Tube in a 95 (Same as '90-96 single tank gas (& '97 over 8500GVWR)); "...Gasoline is extremely volatile in almost all environments, and even diesel is aromatic. Since these vapors can be flammable or noxious, they must be contained & routed to the engine to be burned. But they are produced even when the vehicle is unused for long periods, so a simple tube from the fuel tank to the engine would still allow them to vent out the air filter. Also, during hot weather or violent maneuvers, the quantity of vapor generated can exceed the engine's capacity at low RPM, so the vapors must be stored & their flow regulated. The system begins in the fuel tank where one or more valves are used to vent vapor pressure, but also to exclude liquid from the vapor system due to overfilling, slosh, or rollover. There may also be a pressure sensor to monitor the system's operation & effectiveness, and/or a vent valve (CANV solenoid, or built into the cap) to allow fresh air [b]into[/b] the fuel tank or vapor system. As vapor exits the tank, it flows thru a tube to a canister containing carbon (activated charcoal), which absorbs the fuel vapor, but allows air to pass. Depending on the size of the fuel tank, there may be several canisters, or a larger canister. Older canisters are vented, but they're known to collect water, so most modern canisters are sealed. Another tube leads from the canister toward the engine's intake, but it may contain a regulator valve (CANP solenoid, or VMV). The vapor system may also combine with the PCV system at this point. Being virtually a zero-maintenance system, most faults are simple valve failures, hose leaks, or mechanical damage (collision, road debris, etc.). Faults in the evaporative systems are usually detected by the use of a special machine which pumps a non-toxic non-flammable high-visibility smoke into the vapor lines to make leaks evident. But a common source of evaporative codes on '97-04 vehicles is the operator not securing the fuel filler cap. Earlier vehicles didn't detect this, and later vehicles are designed to exclude this from turning on the CEL..."
Source: by Steve83 (Steve, That dirty old truck) at SuperMotors.net
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Vent Tube pic; "...There is a plastic vent tube inside the filler neck that often gets kinked..." & Causes Gas Station Pump Shuts-Off
Source: by justshootme84 (Randy Z, Casual Mudder) at SuperMotors.net
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Vent Tube Removal & Repairs in an 83 (he did an EFI Swap); "...Loosen the hose clamp at the tank & pull the outer filler neck off the tank. There is another hard plastic hose inside, which also must be removed from the tank.
Source: by Steve83 (Steve, That dirty old truck) at SuperMotors.net
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Vent Tube Replacement w/Extended Info & pics in an 85 (converted to EFI); "...extended 6 more inches over factory..."
Source: by Tim O (RED WAGON, redwagon) at SuperMotors.net
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Vent Tube Replacement w/Extended Info & pics in an 85 (converted to EFI);); "...the steel braided looking line is not actually steel braiding...the inner line is plastic...I found this out when I tried to extend my lines when I raised my tank...I bought 2 feet of actual steel braided line and all fittings ($100.00) and found out they would not work...I ended up taking the fuel lines to the Hose man and he replaced that section on each line with real steel braided hose..."
Source: by Tim O (RED WAGON, redwagon) at FSB
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Vent Tube Replacement w/plastic flex pipe in a 95; "...i have a rubber hose inside my filler pipe and it had been cut off about an inch from where it comes out of the metal filler neck. i couldnt find any fuel hose that size that was for fuel so i got a piece of the plastic flex pipe like for a washing machine and attatched it and put it in. i tried refueling and i could run the nozzle wide open it didnt shut off until it hit 26 gal. which was full. so as long as the plastic holds up i think its fixed..."
Source: by fordsohc46 at Ford Bronco Zone Forums
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Weight, 32 Gal. in 88-96 Bronco; 31.0 lbs (under license from Delmar Publishers, comb of Chilton/Nichols/Delmar & Haynes); some may be incorrect, as reported by Seabronc, thanks Seabronc! NEW SITE URL!!! MUST REGISTER TO VIEW; select year, make, model, engine size and go to appropriate section
Source: by Chilton via AutoZone
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Wiring Diagrams in an 86 Bronco & Ford truck; w/Many Diesel Engine Systems & Components
Source: by Agnem (The Moosestang) at webshots.com
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