Fuel Line Installation Kit # FUEL KIT, TRANS FL, NON-EFI, GM & FORD

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1 Fuel Line Installation Kit #79004 FUEL KIT, TRANS FL, NON-EFI, GM & FORD This kit must be installed by qualified personnel. Read all instructions thoroughly. Park on level surface. Turn vehicle off and disconnect battery KIT# P/N Description Qty SCR, /4-20 X HXHD GRD FLATWASHER, / CLMP, HOSE #6 -/2 MIN -3/4 MAX CABLE TIE, BLACK BULKHEAD FTTG, BARB /8P X /4H FTTG, BARB /8P X 5/6H FUEL FILTER CONN, CORD / BUSHING, SNAP HEYCO GSKT, BULKHD-FUEL LINE HKU BUSHING, OPEN/CLSD 5/8 HOLE NUT, /4-20 HEX NUT, /2-20 HE X JAM SCR, /4-20 X /2 HHCS PLTD HOSE, /4ID FUEL X PUMP, FUEL AIRTEX COVER, FUEL PUMP BASE, FUEL PUMP CD, FUEL PUMP, 2003 VAN EL, 90DEG, /8 X 5/6HB HOSE, FUEL 5/6 X 2, 50PSI VALVE, CHECK, FUEL ASSY, FILLER NECK ADAPTER X 2.5 FUEL HOSE FTTG, 5/6HB X 5/6 FORD ELL, 5/6HB X 5/6 FORD FILTER, FUEL, 5/6 HOSE 8762 WASHER, /4 SPLIT LOCK SHT, WARN, FUEL CHK VLV INST, FUEL KIT GM & FORD, NON-EFI 7965 FTTG, CAP, 5/6 FORD FUEL CLMP, F.I., SAE 2, /4 HOSE CLMP, F.I., SAE 4, 5/6 HOSE 2 FUEL LINE INSTALLATION INSTRUCTIONS # B 07/26/05 of

2 03-05 GM/04-05 FORD WITHOUT AUX FUEL PORT OPTION INSTRUCTIONS: NOTE: Read these instructions entirely before proceeding. These instructions are for GM/04-05 FORD vans without factory installed auxiliary fuel ports. DO NOT damage the vehicle in any manner during installation. When routing fuel lines DO NOT place the hose in any location where damage may occur to the hose or vehicle. Avoid any contact with moving parts, areas of high temperature, brake lines, fuel lines, muffler, catalytic converter, or sharp objects. FUEL PUMP INSTALLATION (ALL MODELS): Before drilling the fuel line holes in the vehicle floor, make certain that you will not do any damage to the fuel tank, fuel lines, brake lines, heat shields, or any other vital component which might affect the operation or safety of the vehicle. Do not install this assembly in any manner or position which, in so doing, may cause damage to the vehicle or any component which might affect the operation or safety of the vehicle.. Determine the mounting location of the fuel pump box assembly. Check to ensure that the power cord length will support the mounting location. The pump should be mounted as low as possible and still be protected by the frame from road hazards. Mount the fuel pump with the discharge side of the pump higher than the suction side to eliminate the possibility of trapped air in the pump. The pump end with the electrical connections is the discharge end. See Figure 5. Additional mounting holes are provided to allow for different mounting options. See Figure. 2. Cut a 6 piece of 5/6 fuel hose (79082) and connect from the outlet side of the fuel filter (79073) to the inlet side of the fuel pump (790549). Use supplied hose clamps ( ) and fasten securely. Do not mount this assembly near the catalytic converter, exhaust, or any areas of high temperature. 3. Prior to drilling, check to ensure that the cord length will support the location of the hole. Drill a 5/8 hole in the vehicle floor for routing the fuel pump power cord to the truckmount console. See Figure. 4. Connect the power cord to the fuel pump and install the hole grommet ( ) as shown in Figure. 2 of

3 5. Do not connect the power cord to the truckmount console wiring harness until installation is complete. FUEL PICKUP TUBE INSTALLATION (GM vans) This kit is designed to be used on a fuel injected gas GM G-van with a 3.0 gallon midship front fill plastic fuel tank and no left hand sliding door. The following instructions are written with the assumption that the entire installation would be completed without running the engine or moving the vehicle. The instructions were also written with the assumption that the installation would be completed the same day that it was started. If either of these assumptions is incorrect, the installer must follow these additional instructions. If the filler neck adapter tube is installed into the vehicle s fuel fill tube, the installer must properly seal the supply and return tubes on the filler neck adapter tube until the supply and return hoses are connected. The components used to seal the pickup tube ports, must be capable of withstanding direct contact with fuel and must remain attached when an internal pressure of 5 psi is applied to the inside of the tube ports. If the filler neck adapter tube is installed into the vehicle s fuel fill tube, and the supply and return ports are left unsealed, fuel may leak out of these connections. Fuel leaking on the vehicle chassis and onto the ground could create a fire hazard and a hazardous material cleanup. If the filler neck adapter tube is installed into the vehicle s fuel fill tube, and the supply and return ports are left unsealed, the check engine light on the vehicle may illuminate. Many vehicles have the enhanced evaporative leak detection program activated. When the vehicle s engine is operating, a leak detection test may occur. If a leak in the fuel system is detected, the check engine light will illuminate.. It will be necessary to remove the fuel fill tube and the ground strap in order to have room to complete the installation. 2. Remove the screws that secure the fillneck to the bezel. Remove the screws that secure the bezel to the fuel door pocket housing. Remove the bezel from the vehicle. 3. Remove the OEM fillneck and the OEM -/4 to -/8 I.D. molded fill hose connected to the fuel tank. 4. Remove the plastic fill tube shield by cutting the wire ties to expose the -/4 to -/8 I.D. molded fill hose. 5. Measure the OEM -/4 to -/8 I.D. molded fill hose from the edge that attaches to the fuel tank out to 2.5. Mark and cut the fill hose. The 2.5 long piece will connect between the upper fillneck and the filler neck adapter tube. Discard the 3.5 to 4.0 long piece of hose. Save the OEM clamp. 3 of

4 6. Place the provided 2-/2 long x -/4 I.D. (7909) filler neck adapter hose onto the OEM fuel tank. Slide the (2) #6 clamps ( ) in place and install the filler neck adapter tube (790865) with the flapper down and with supply and return tubes facing to the rear of the vehicle. The plastic draw hose on the filler neck adapter tube assembly has to go down through the notch in the OEM tank filler neck. When installing, position the fuel pickup tube close to the interior fuel tank wall. Secure the two hose clamps. Set the torque of both clamps to 25 in-lb ± 5 in-lb. ELL, 90DEG, /4P X 5/6HB, BR 7. Reinstall the OEM fillneck using the OEM hose clamp. Set the torque of the clamp to 25 in-lb ± 5 in-lb. If the plastic draw hose is not located in the notch, the hose may interfere with the OEM sending unit float operation. 8. Place the bezel back into its previous location. Secure the bezel to the fuel door pocket housing. Secure the fillneck to the bezel. NOTE: The 5/6 supply draw tube on the filler neck adapter tube (790865) should be facing to the rear of the vehicle at the 4:30 o clock position. The 5/6 return tube on the filler neck adapter tube will be located at the o clock position. FUEL LINE INSTALLATION INS TRUCTIONS B 07/26/05 4 of

5 FUEL PICKUP TUBE INSTALLATION & MODIFICATION (FORD vans) This kit is designed to be used on a FORD fuel injected gas van. The following instructions are written with the assumption that the entire installation would be completed without running the engine or moving the vehicle. The instructions were also written with the assumption that the installation would be completed the same day that it was started. If either of these assumptions is incorrect, the installer must follow these additional instructions. If the filler neck adapter tube is installed into the vehicle s fuel fill tube, the installer must properly seal the supply and return tubes on the filler neck adapter tube until the supply and return hoses are connected. The components used to seal the pickup tube ports, must be capable of withstanding direct contact with fuel and must remain attached when an internal pressure of 5 psi is applied to the inside of the tube ports. If the filler neck adapter tube is installed into the vehicle s fuel fill tube, and the supply and return ports are left unsealed, fuel may leak out of these connections. Fuel leaking on the vehicle chassis and onto the ground could create a fire hazard and a hazardous material cleanup. If the filler neck adapter tube is installed into the vehicle s fuel fill tube, and the supply and return ports are left unsealed, the check engine light on the vehicle may illuminate. Many vehicles have the enhanced evaporative leak detection program activated. When the vehicle s engine is operating, a leak detection test may occur. If a leak in the fuel system is detected, the check engine light will illuminate.. Remove the OEM fillneck and the OEM -/2 to -/8 molded fill hose connected to the fuel tank. 2. Measure the OEM -/2 to -/8 I.D. molded fill hose from the end that attaches to the fuel tank out to 3.5. Mark and cut the fill hose. The 3.5 long piece will connect between the fuel tank and the filler neck adapter tube. Cut an additional from the remaining section of -/8 fill hose and discard. 3. Remove the plastic valve in the filler neck at the fuel tank and discard. 4. Cut the 5/6 metal pickup tube on the filler neck adapter tube (790865) 3 below the -/4 tube. Cut a 3 length of 5/6 fuel hose (79082) and add between the two pieces of 5/6 metal tube. Fasten securely with supplied hose clamps ( ). Cut the pickup tube off between the bend and the plastic tube. Discard bend, clean and deburr end of tube. See Figure Place the 3-/2 long x -/2 I.D. molded filler neck hose onto the fuel tank. Slide the (2) #6 clamps in place and install the filler neck adapter tube (790865) with the flapper down and the supply and return tubes facing to the rear of the vehicle. The plastic draw hose on the filler neck adapter tube assembly has to go down through the notch in the OEM fuel tank inlet. When installing, position the fuel pickup tube close to the interior fuel tank wall. Secure the two hose clamps. Set the torque of both clamps to 25 in-lb ± 5 in-lb. 5 of

6 6. Reinstall the OEM fillneck using the OEM hose clamp. Set the torque of the clamp to 25 in-lb ± 5 in-lb. NOTE: The 5/6 supply draw tube on the filler neck adapter tube (790865) should be facing to the rear of the vehicle at the 4:30 o clock position. The 5/6 return tube on the filler neck adapter tube will be located at the o clock position. SUPPLY LINE FROM FUEL TANK INSTALLATION (GAS TANK TO FUEL PUMP) (ALL MODELS). Spray the inside of the supplied straight plastic barbed fitting with WD-40 or equivalent. Push plastic fitting onto the supply tube on filler neck adapter tube (790865) until fitting securely snaps into place. 2. Cut a 6 length of 5/6 fuel hose (79082) and attach between the plastic barbed fitting and the inlet side of the fuel filter (79073) making sure to avoid hot or sharp objects. Fasten securely using supplied hose clamps ( ). 6 of

7 VAN BULKHEAD INSTALLATION (ALL MODELS) Before drilling the fuel line hole in the vehicle floor, make certain that you will not do any damage to the fuel tank(s), fuel lines, brake lines, heat shields, or any other vital component which might affect the operation or safety of the vehicle.. Select a location on the vehicle floor to drill two holes for the bulkhead adapters. This location should be situated in a position that eliminates the possibility of fuel line contact by either the operator(s) or accessories during the working hours or maintenance periods. Make certain that the supplied hoses will reach the location and work with the configuration you choose. See figure. 2. Drill a 5/8" (.625) diameter hole through the vehicle floor at the installation point chosen for each bulkhead. 3. Install the two /8 NPT bulkhead adapters (-80009) by inserting the adapter and tightening the nut on the opposite side of the van floor. Install the two /8P x 5/6HB elbow fittings (790605) on to the bulkheads (underside of van) clocked in a direction to allow easy access to fuel hose and clear of hot or sharp objects. See Figures 2 & 3. SUPPLY & RETURN LINE INSTALLATION (UNDERSIDE OF VAN) (ALL MODELS). Spray the inside of the supplied 90 degree plastic barbed fitting with WD-40 or equivalent. Push plastic fitting onto the return tube on filler neck adapter tube (790865) until fitting securely snaps into place. 2. Measure and cut a length of 5/6 fuel return line (79082) and connect between the 5/6H barb fitting (790605) at the bulkhead and the plastic barbed fitting on the return tube of the filler neck adapter tube (790865). Fasten securely using supplied hose clamps ( ). See Figure Measure and cut a length of 5/6 fuel hose (79082) and connect between the outlet side of the fuel pump and the 5/6H barb fitting (790605) at the bulkhead for the supply line. Fasten securely using supplied hose clamps ( ). See Figure Locate an easily serviceable location on the return line. Cut return hose and install check valve (790859) and secure with supplied hose clamps ( ). See Figure 3. NOTE: Arrow on check valve should point towards the filler neck adapter tube. When routing the hoses and cord underneath the vehicle make certain that you do not place them in any location where damage may occur. 7 of

8 SUPPLY & RETURN LINE INSTALLATION (CARGO AREA) (ALL MODELS). Attach a /8NPT x 5/6H barb fitting ( ) to the bulkhead with the fuel supply line. See Figures 2 & Attach a /8NPT x /4H barb fitting ( ) to the bulkhead with the fuel return line. See Figures 2 & Measure and cut a length of 5/6 fuel hose (79082) and connect between the 5/6H barb fitting ( ) at the bulkhead and the 5/6H barb fitting on the console fuel bracket. Fasten securely using supplied hose clamps ( ). See Figure 3. NOTE: On units with two barb fittings on the console fuel bracket, a bypass filter is installed near the engine. On units with a supply line only barb fitting on the console fuel bracket (Blazer XL & Legend XL), cut and remove a section of fuel hose and install supplied bypass filter ( ). See Figure Measure and cut a length of /4 fuel hose (790548) and connect between the /4H barb fitting ( ) at the bulkhead and the /4H barb fitting on the console fuel bracket or the /4 bypass port on the bypass filter. Fasten securely using supplied hose clamps ( ). See Figure Connect fuel pump cord to console wiring harness. 6. Check for fuel leaks. 8 of

9 BULKHEAD CONNECTOR (FUEL LINE FROM CONSOLE) BULKHEAD CONNECTOR TO FRONT OF VAN /6" FUEL SUPPLY HOSE ELECTRIC FUEL PUMP ASSEMBLY FUEL FILTER FROM VEHICLE FUEL TANK 5/6" FUEL RETURN LINE ELECTRIC FUEL PUMP POWER CORD 5/6" FUEL HOSE VIEW FROM UNDERNEATH VAN FIGURE FUEL HOSE HOSE CLAMP TO FUEL INLET OR OUTLET ON CONSOLE BARB FITTING LOCTITE 545 VEHICLE FLOOR HOSE CLAMP BULKHEAD ADAPTER LOCTITE 545 FUEL HOSE FIGURE 2 HOSEBARB ELBOW 9 of

10 TO FUEL BRACKET ON CONSOLE FACTORY INSTALLED CLAMPS OUTLET SIDE (4) FLOW HOSE IS SUPPLIED IN ONE PIECE, CUT TO LENGTH AS NEEDED. FIGURE 3 FUEL LINE HOOK-UP CUT OFF BEND AND DISCARD FIGURE 4 FORD MODIFICATION TO FILLER NECK ADAPTER TUBE 0 of

11 (6) (6) (2) (6) OUTLET SIDE (4) 8762 (4) 7027 (4) INLET SIDE (2) 8762 (6) (6) FIGURE 5 FUEL INLET BRACKET ON CONSOLE TO FUEL BRACKET ON CONSOLE (6) (4) (2) (2) (2) (2) 5722 PEAK, NON-EFI EVEREST & APEX BLAZER XL & LEGEND XL FIGURE 6 of

Do not have any open flame or heat sources close to the installation

Do not have any open flame or heat sources close to the installation March 6, 2017 IS# 791 Page 1 of 16 Thank you for purchasing a Transfer Flow, Inc. 50-gallon replacement fuel system for your 2011-16 Ford diesel short bed pickup. This system will fit any 2x4 or 4x4 crew