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Thread: The Electric Fuel Conversion on my 97 F-350

  1. 10-09-2011, 09:55 PM #1
    LovesDunes
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    The Electric Fuel Conversion on my 97 F-350

    I posted this on another site but thought you guys might like to have it over here too.

    I had a small fuel leak for a while and no time to fix it since I have been so busy. I've been driving the Blazer but with the rain and the cold I wussed out and started driving the truck. Well it seems the mechanical fuel pump in my truck is only good for about 150,000 miles. This is the second one. So for the second time in its life my truck got a ride home...






    It's great actually that this has happened. Now I have to fix it.
    So the plan is to replace the mechanical pump with an electric one. I'll have a 10 micron filter/water seperator before the pump and a 2 micron filter after the pump. All of this gets mounted down below on the frame. It's nice because it will help clean up the engine compartment.
    Because right now it's a mess.
    Last edited by LovesDunes; 10-10-2011 at 01:38 AM.
    1997 F-350 XLT 4x4, Crew Cab, Long Bed.
    John Woods Transmission, Banks Powerpack, Custom Reverse Shakle Kit, National Springs, Fox Shocks, 38.5" Pro-Comp Xtreme All Terrains, 4:56 Gears with Detroit Lockers front and rear, Modified front driveshaft, Warn Premium Hubs, Electric Fuel Conversion.

    320,000+ Miles
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  2. 10-09-2011, 09:56 PM #2
    LovesDunes
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    Here's most of the tubing removed...


    Here's the turbo out...



    That thing is a pain to remove.


    With the turbo and intercooler tubing removed you can see the fuel pump and the mess it's made...


    The fuel pump and the filter housing go away...

    The plan is to re-use the fuel lines that feed the injectors.
    Last edited by LovesDunes; 10-10-2011 at 12:36 AM.
    1997 F-350 XLT 4x4, Crew Cab, Long Bed.
    John Woods Transmission, Banks Powerpack, Custom Reverse Shakle Kit, National Springs, Fox Shocks, 38.5" Pro-Comp Xtreme All Terrains, 4:56 Gears with Detroit Lockers front and rear, Modified front driveshaft, Warn Premium Hubs, Electric Fuel Conversion.

    320,000+ Miles
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  3. 10-09-2011, 09:57 PM #3
    LovesDunes
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    I removed the pedestal and took apart the EBPV just to see what was inside.
    It looks like I had a leak at the down pipe...


    I definitely had an oil leak where the rod comes out of the housing for the EBPV...


    Maybe it's the o-rings under the pedestal or the EBPV but it looks like a leak over here too...


    And more leaking around the housing...

    1997 F-350 XLT 4x4, Crew Cab, Long Bed.
    John Woods Transmission, Banks Powerpack, Custom Reverse Shakle Kit, National Springs, Fox Shocks, 38.5" Pro-Comp Xtreme All Terrains, 4:56 Gears with Detroit Lockers front and rear, Modified front driveshaft, Warn Premium Hubs, Electric Fuel Conversion.

    320,000+ Miles
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  4. 10-09-2011, 09:57 PM #4
    LovesDunes
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    Removing the pedestal was easy enough. Just the four 10mm bolts at the bottom...


    Linkage on the end has a cool spring loaded dealeo...


    It was easy to remove...



    O-Rings...




    The cross section on the o-rings is different. Or maybe it's because they have been compressed for so long.

    Last edited by LovesDunes; 10-10-2011 at 12:38 AM.
    1997 F-350 XLT 4x4, Crew Cab, Long Bed.
    John Woods Transmission, Banks Powerpack, Custom Reverse Shakle Kit, National Springs, Fox Shocks, 38.5" Pro-Comp Xtreme All Terrains, 4:56 Gears with Detroit Lockers front and rear, Modified front driveshaft, Warn Premium Hubs, Electric Fuel Conversion.

    320,000+ Miles
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  5. 10-09-2011, 09:58 PM #5
    LovesDunes
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    The pedestal is a mess...




    Last edited by LovesDunes; 10-10-2011 at 12:39 AM.
    1997 F-350 XLT 4x4, Crew Cab, Long Bed.
    John Woods Transmission, Banks Powerpack, Custom Reverse Shakle Kit, National Springs, Fox Shocks, 38.5" Pro-Comp Xtreme All Terrains, 4:56 Gears with Detroit Lockers front and rear, Modified front driveshaft, Warn Premium Hubs, Electric Fuel Conversion.

    320,000+ Miles
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  6. 10-09-2011, 10:00 PM #6
    LovesDunes
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    The EBPV (Exhaust Back Pressure Valve) comes apart easy enough.

    Remove the snap ring...


    A little tapping on the link from the other end...



    The dust seal wasn't doing too great a job...


    The inside of the housing was full of crud...


    The rubber seal on the piston was as hard as a rock. That would explain all of the oil on the wrong side of the piston leaking out the hole where the linkage exits...


    Since I have never seen the inside of the turbo housing I took it apart too...





    I'm not sure how this electrical thing works. It's mounted on a big bolt looking thing...


    Last edited by LovesDunes; 10-10-2011 at 12:40 AM.
    1997 F-350 XLT 4x4, Crew Cab, Long Bed.
    John Woods Transmission, Banks Powerpack, Custom Reverse Shakle Kit, National Springs, Fox Shocks, 38.5" Pro-Comp Xtreme All Terrains, 4:56 Gears with Detroit Lockers front and rear, Modified front driveshaft, Warn Premium Hubs, Electric Fuel Conversion.

    320,000+ Miles
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  7. 10-09-2011, 10:04 PM #7
    LovesDunes
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    I got the fuel bowl and the fuel pump off. The rubber fuel lines were reeaalllly hard and didn't want to let go of the metal lines so I ended up just cutting through the rubber lines.




    After cutting those I thought it was going to come out. But the one at the bottom didn't want to let go either...


    It was harder to cut with the lack of space but this blade made it easier...

    Last edited by LovesDunes; 10-10-2011 at 12:41 AM.
    1997 F-350 XLT 4x4, Crew Cab, Long Bed.
    John Woods Transmission, Banks Powerpack, Custom Reverse Shakle Kit, National Springs, Fox Shocks, 38.5" Pro-Comp Xtreme All Terrains, 4:56 Gears with Detroit Lockers front and rear, Modified front driveshaft, Warn Premium Hubs, Electric Fuel Conversion.

    320,000+ Miles
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  8. 10-09-2011, 10:05 PM #8
    LovesDunes
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    So I got the fuel bowl almost out but I found these wires still holding on...


    This one pulled right off...


    Whatever that one wire was plugged into unscrews...


    So that this thing can be rotated clockwise...



    And pulled from the bowl...


    But even pulling those loose would not let me pull the fuel bowl from the truck. The plugs would not slip through this hole...


    So I ended up cutting the wires to get the fuel bowl out...

    Last edited by LovesDunes; 10-10-2011 at 12:42 AM.
    1997 F-350 XLT 4x4, Crew Cab, Long Bed.
    John Woods Transmission, Banks Powerpack, Custom Reverse Shakle Kit, National Springs, Fox Shocks, 38.5" Pro-Comp Xtreme All Terrains, 4:56 Gears with Detroit Lockers front and rear, Modified front driveshaft, Warn Premium Hubs, Electric Fuel Conversion.

    320,000+ Miles
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  9. 10-09-2011, 10:06 PM #9
    LovesDunes
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    I took the fuel pressure regulator off of the bowl just because. You can see the screen that people are always saying to clean...


    Mine was nice and filthy...


    I took the bottom apart to see what was inside...






    There is some sort of screen filter looking thing in there...


    Of course that's dirty too...

    Last edited by LovesDunes; 10-10-2011 at 12:43 AM.
    1997 F-350 XLT 4x4, Crew Cab, Long Bed.
    John Woods Transmission, Banks Powerpack, Custom Reverse Shakle Kit, National Springs, Fox Shocks, 38.5" Pro-Comp Xtreme All Terrains, 4:56 Gears with Detroit Lockers front and rear, Modified front driveshaft, Warn Premium Hubs, Electric Fuel Conversion.

    320,000+ Miles
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  10. 10-09-2011, 10:06 PM #10
    LovesDunes
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    I removed the flap that the EBPV used to control...


    Even when it's open that flap and the shaft actually take up a bit of room...


    A 12 points , 8mm wrench along with a hammer took the 3 bolts out the hold the housing in place...


    Here's the housing on the bench....





    So the plan was to grind off the smaller part of the rivets...



    And then hammer through to the other side and remove the flap...


    But those things wern't about to let go...


    So I ended up grinding off the larger head...



    Even with the rivets out of the way the flap did not want to come off...


    I was amazed at how much wear was on the end of the flap...


    Now with the flap gone the rivets come right out...


    With the rivets gone the shaft pulls right out...


    Here's the hole where the shaft came out showing the bushing I need to pound out...


    Here's the other side all nice and plugged up...


    To drive out the old bushing, I used this old sleeve I found on the garage floor...


    All pounded out...


    Now I'm off to get a 20mm freeze flug to fill the hole.

    It's wide open now...
    Last edited by LovesDunes; 10-10-2011 at 12:45 AM.
    1997 F-350 XLT 4x4, Crew Cab, Long Bed.
    John Woods Transmission, Banks Powerpack, Custom Reverse Shakle Kit, National Springs, Fox Shocks, 38.5" Pro-Comp Xtreme All Terrains, 4:56 Gears with Detroit Lockers front and rear, Modified front driveshaft, Warn Premium Hubs, Electric Fuel Conversion.

    320,000+ Miles
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  11. 10-09-2011, 10:07 PM #11
    LovesDunes
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    Got the 20mm freeze plug...


    I used an 11mm socket to get the freeze plug started...



    Then I switched over to a sleeve that I found with the other sleeve I used earlier...




    Then I switched over to a 10mm socket to get it the rest of the way in. The 11mm socket would not fit any more...


    Then I ran a wire wheel around the whole assembly to clean it up...




    Last edited by LovesDunes; 10-10-2011 at 12:46 AM.
    1997 F-350 XLT 4x4, Crew Cab, Long Bed.
    John Woods Transmission, Banks Powerpack, Custom Reverse Shakle Kit, National Springs, Fox Shocks, 38.5" Pro-Comp Xtreme All Terrains, 4:56 Gears with Detroit Lockers front and rear, Modified front driveshaft, Warn Premium Hubs, Electric Fuel Conversion.

    320,000+ Miles
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  12. 10-09-2011, 10:08 PM #12
    LovesDunes
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    As if I didn't have enough to do my buddy Mr Woods talked me into a new oil pump and regulator.





    Last edited by LovesDunes; 10-10-2011 at 12:47 AM.
    1997 F-350 XLT 4x4, Crew Cab, Long Bed.
    John Woods Transmission, Banks Powerpack, Custom Reverse Shakle Kit, National Springs, Fox Shocks, 38.5" Pro-Comp Xtreme All Terrains, 4:56 Gears with Detroit Lockers front and rear, Modified front driveshaft, Warn Premium Hubs, Electric Fuel Conversion.

    320,000+ Miles
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  13. 10-09-2011, 10:09 PM #13
    LovesDunes
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    The fuel pump was a pain to remove. It just didn't want to let go...


    But it did finally come out...



    When removing the pump it's REALLY important that the plunger not get dropped into the engine...



    With the pump out you can see the mess in the valley. The puddles of fuel are a nice shade of blue
    Last edited by LovesDunes; 10-10-2011 at 12:53 AM.
    1997 F-350 XLT 4x4, Crew Cab, Long Bed.
    John Woods Transmission, Banks Powerpack, Custom Reverse Shakle Kit, National Springs, Fox Shocks, 38.5" Pro-Comp Xtreme All Terrains, 4:56 Gears with Detroit Lockers front and rear, Modified front driveshaft, Warn Premium Hubs, Electric Fuel Conversion.

    320,000+ Miles
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  14. 10-09-2011, 10:09 PM #14
    LovesDunes
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    I was looking at the mess under the hood and was about to do the swap on the pump and noticed the plug to the regulator was missing. Then I realised that the plug for the IPR was in part of the harness I cut to remove the fuel bowl. I found the plug but it's a complete mess. It appears to have shorted out a long time ago. So I can't imagine that it was doing its job.





    So now I need to get one of those.
    1997 F-350 XLT 4x4, Crew Cab, Long Bed.
    John Woods Transmission, Banks Powerpack, Custom Reverse Shakle Kit, National Springs, Fox Shocks, 38.5" Pro-Comp Xtreme All Terrains, 4:56 Gears with Detroit Lockers front and rear, Modified front driveshaft, Warn Premium Hubs, Electric Fuel Conversion.

    320,000+ Miles
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  15. 10-09-2011, 10:10 PM #15
    LovesDunes
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    My pre-filter finally got here...


    It's a lot larger than I thought it was going to be...


    Nifty bowl for collecting water...


    Is screws into the bottom of the filter...



    To remove the filter the ring is turned to unlock the filter from the base...
    1997 F-350 XLT 4x4, Crew Cab, Long Bed.
    John Woods Transmission, Banks Powerpack, Custom Reverse Shakle Kit, National Springs, Fox Shocks, 38.5" Pro-Comp Xtreme All Terrains, 4:56 Gears with Detroit Lockers front and rear, Modified front driveshaft, Warn Premium Hubs, Electric Fuel Conversion.

    320,000+ Miles
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