7.3 Power Stroke Fuel Filter Housing Removal

7.3L Power Stroke Fuel Filter Housing Removal & Installation Procedures

Procedures that require the fuel filter housing to be removed include replacing the fuel pump, rebuilding the housing/fixing a leak, replacing a high pressure oil pump, and installing a new IPR valve. The filter housing is located in the center of the engine valley just behind the HPOP reservoir. It mounts to the engine block and has a series of fuel lines that must be removed and replaced anytime the housing is pulled from the vehicle. The following procedures are applicable to 1994.5 - 1998 model year engines only.

Applicable Model Years: 1994.5 - 1998 Ford F-Series, 7.3L Power Stroke
Fuel filter housing/fuel pump lines: see table below
Fuel filter w/ gasket: Ford F4TZ-9N184-A
Fuel filter housing cap: Ford F5TZ-9G270-A

7.3L Power Stroke Fuel Pump/Filter Housing Fuel Line Guide

When replacing fuel lines, it is advantageous to use new hose clamps. The lines from International/Ford are high pressure, high quality hoses. Standard low pressure fuel lines CANNOT be used in place of these part numbers, with the exception of the fuel drain valve hose - 5/16" I.D. standard low pressure hose can be substituted. Note that not all hoses below are required to be replaced, only those that are removed and/or damaged.

Description

Location

Color

ID

Length

Part Number

Fuel tank to fuel pump

Driver side of fuel pump

Blue

3/8 in

~ 2.25 in

International 1818394C2

Ford F4TZ-9324-DA

Fuel filter housing to fuel pump

Passenger side of fuel pump

Blue

3/8 in

~ 3.25 in

International 1818393C2

Ford F4TZ-9324-CA

Motorcraft KL34

Fuel pump to water separator

Bottom of fuel pump

Blue

3/8 in

~ 2.25 in

International 1818394C2

Ford F4TZ-9324-DA

Fuel pressure regulator to tank return

Driver side, fuel pressure regulator

Black

5/16 in

~ 1.5 in

International 1821623C2

Motorcraft KL33

Fuel filter housing drain tube

Passenger side, bottom of drain valve

Black

5/16 in

~ 1.5 in

International 1821623C2

Motorcraft KL33

Fuel pressure regulator bypass hose

Bottom of fuel filter housing to FPR
1994 - 1995 MY only
Typically serviced during fuel filter housing rebuild

Blue

3/8 in

~ 6 in

Ford F5TZ-9C024-A

Passenger side fuel return

Threaded return line
Passenger side cylinder head to FPR

Black

N/A

N/A

Ford F4TZ-9B273-A

Driver side fuel return

Threaded return line
Driver side cylinder head to FPR

Black

N/A

N/A

Ford F4TZ-9D308-A

Fuel Filter Housing/Fuel Bowl Removal

Note - the turbocharger is shown removed in the following images. The turbocharger does NOT need to be removed in order to remove the fuel filter housing.

Click any thumbnail to view high resolution fullsize image w/ addition details (where applicable)

fuel bowl location

• Attach a section of 5/16" fuel line to the fuel drain valve outlet (against front of engine block on passenger side). Drain the fuel filter housing into a suitable container by opening the drain valve at the front of the fuel filter housing (yellow lever).

• Once the fuel filter housing has drained, remove the fuel filter and discard it. Replace the fuel filter housing cap and close the drain valve.

fuel drain valve

• Loosen the clamp on the fuel drain valve hose. The nipple for the fuel drain valve is located several inches below the yellow drain valve handle. A long screw driver will be necessary to reach the clamp.

• Unplug the fuel filter housing sensor harness (passenger side of housing).

• Unplug the IPR valve connector (driver side of high pressure oil pump).

fuel pump hoses

• Loosen the clamps for all three blue hoses on the fuel pump. The driver side hose does not actually connect to the fuel filter housing, but should be replaced regardless since the others will be. The passenger side hose and lower hose connect to the fuel filter housing.

tank return hose

• Loosen the clamp for the black rubber line connecting the fuel pressure regulator to the fuel tank return line. Slide the hose downwards (away from fuel pressure regulator) onto the hard metal line until it is no longer connected to the fuel pressure regulator.

fuel return lines disconnected

• Remove the fuel return lines from the fuel pressure regulator (front, driver side of fuel filter housing, threaded fittings).

fuel filter housing bolt locations

• The fuel filter housing is secured to the engine block by (2) bolts. Remove them with a 10 mm socket and the necessary extensions.

• Lean the fuel filter housing towards the firewall and disconnect the fuel drain valve line.

• Lean the fuel filter housing towards the radiator and work off the two fuel pump lines. They tend to get hard and become stubborn to remove. Twisting them side-to-side while pulling seems to work well in working them off.

Fuel Filter Housing/Fuel Bowl Installation

There are several methods for reinstalling the fuel filter housing. This technique works for us, although you may find an alternative arrangement of the steps below works better for you.

fuel bowl removed

• Verify the length of all hoses by comparing them to those that were removed; the long hose connecting the housing to the fuel pump may need to be trimmed to the proper length.

• Replace the fuel hose that connects the vacuum side inlet of the fuel pump (top hose, driver side) to the metal fuel tank line using new clamps.

• Install the new fuel hose for the fuel pressure regulator (FPR) to metal tank return line (small black hose) with new clamps. Slide the hose down the metal line so that the FPR fitting can be set against the metal line.

installing new fuel lines

• Install the remaining blue fuel lines onto the fuel filter housing and clamp them down. Verify the length of the upper blue hose - it may need to be cut to match the length of the old hose.

• Install the drain valve hose at the fuel filter housing and clamp down.

• Slide the second clamp for all three lines loosely over the hoses.

rebuilt fuel filter housing

• Set the fuel bowl into place. Slide the drain valve hose onto the metal drain valve line. Slide the housing towards the fuel pump to set the depth that the metal line fits into the hose, then tighten down the clamp before installing any other fuel lines.

• Plug in the IPR connector.

• Plug in the fuel filter harness to the engine harness connector (passenger side of filter housing).

new fuel lines installed

• Slide the filter housing towards the fuel pump and install the two remaining blue hoses to their respective locations on the fuel pump. The lines are tight and this can be tricky - we find it easiest to install the bottom line first, following by the top line. Tighten down all hose clamps.

• Line up the holes and install the (2) retaining bolts that secure the fuel filter housing to the engine block and tighten snug with a 10 mm socket.

fuel bowl reinstalled

• Slide the fuel tank return line hose (small black hose) onto the FPR nipple and tighten both hose clamps.

• Reinstall both fuel return lines (threaded lines) at front of the fuel filter housing.

• Make sure the fuel filter drain valve/water separator drain valve is closed. Install a new fuel filter and gasket (coat gasket in clean engine oil before installation).

• Fill the filter housing with clean diesel before starting engine - this will reduce the amount of cranking required to start the engine. Start engine and thoroughly check for fuel leaks.