6.0L Power Stroke Diesel2003 - 2007 F250, F350 pickup and F350+ Cab Chassis, 2003 - 2005 Excursion and 2003 - 2009 van
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SMOKING OR AN OPEN FLAME OF ANY TYPE IS PROHIBITED WHEN WORKING NEAR FUEL OR FUEL VAPOR.
Disconnect both battery ground cables. Refer to Workshop Manual, Section 414-01.
Raise and support the vehicle. Refer to Workshop Manual, Section 100-02.
Open the fuel/water separator drain plug to release contents (Figure 1).
Figure 1 - Article 06-6-5
Disconnect the fuel pump, heater, water in fuel electrical connectors from HFCM (Figure 2).
Figure 2 - Article 06-6-5
Disconnect HFCM electrical harness from main vehicle harness.
Disconnect the fuel hoses from HFCM.
Remove the fuel hose retaining clips and discard. Disconnect the fuel hoses closest to the engine (Figure 3 number 1).
Figure 3 - Article 06-6-5
Press in the retaining clips and release the fuel hoses closest to the fuel tank (Figure 3 number 2).
Remove the screws and the old fuel manifold cover (Figure 4).
Figure 4 - Article 06-6-5
Inspect/clean debris from the HFCM water reservoir housing (max. 25 psi air).
Install the new manifold and screws and torque to 44 lb-in (5 N-m) (Figure 5).
Figure 5 - Article 06-6-5
Install the new electrical harness and reconnect/reinstall fuel lines. Electrical harness will have connectors for the pump, for the water in fuel sensor, and one that connects to the main vehicle harness.
Verify that there are no fuel leaks from the HFCM.
Remove and discard heater 30 amp (J-case style) heater fuse.
For 2003-2004 Model Years, remove 30 amp Fuse F2.105 located in Central Junction Box (CJB). Refer to 2003 or 2004 Ford F-Super Duty (F250/350) Wiring Diagrams (EVTM), Section 11 (pages 1-3).
For 2005 Model Year, remove 30 amp Fuse F1.7 located in the engine Battery Junction Box (BJB). Refer to 2005 Ford F-Super Duty (F250/350) Wiring Diagrams, Section 11 (pages 4-5).
DO NOT REINSTALL HEATER FUSE (FUSE IS NOT REQUIRED WITH NEW HFCM MANIFOLD).
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