Join Date: Mar 2000
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Re: 5.0 is alive kinda!!!!!!!!
For the TJ, the fuel system will be very easy.
Remove your gas tank sending unit from the tank, and install a 93 Mustang 5.0 pump, and sock filter onto the TJ sending unit. It should adapt fairly simple, in fact if you have trouble with this portion of project, you are in for a long difficult swap. In the case of the YJ, its just a matter of cutting the rubber hose, in the install package to fit snuggly in the housing, then using a hose clamp in the middle of the rubber hose to attach the hose to the sending unit frame.
The 5.0 uses Ford spring clip fasteners at several locations along the stainless runners. Pull off the last section of stainless fuel tubing on both the supply and return line at the engine(you will need a Ford special tool that allows you to seperate the sections without damage). Take the sections to an industrial hose or Automotive hose suppl house in your area, and have them double flair the stainless tubing with AN fittings on the outer ends of both lines. Then you can just reinstall the stainless fuel tubing to the existing lines, and run stainless braided hose with AN fitting right up to your modified Ford fuel tubes. Cost will be about $100 if you run braided stainless and annodized fittings through the entire system. The stainless lines will simply onto the hump of the sending unit fittings and can be clamped with a high pressure fuel line clamp. The clamps and even the Ford fuel line tool are available at nearly any auto parts.
I use a Mustang fuel filter along the rail in the gas tank compartment.
A very usefull modification while you are doing this portion of the project, is to make an access panel in the rear bed that will allow easy access to the sending unit cover bolts, and fuel filter. You can mount a small compartment that can house a spare fuel pump in a thick baggy with a little motor oil in it, along with spare clamps and fittings, specialized fuel tools and pump filter sock.. If you or a friend ever need to repair or replace your fuel pump or lines, you will look like the wise old sage when you open up your easy access to the sending unit and are back on the trail in 5 minutes.(buy lifetime warrantied pumps and just replace the bad one return it and put the new replacement into the rotation.
Another good idea for the 5.0 is to install an aftermarket adjustable fuel regulator, it will help you maintain a much more steady low idle. Also make sure to adjust the throttle position sensor to within Fomoco specs.