1994-97 Ford Powerstroke Racor Unit Installation
Locate fuel supply line coming from tank on the drivers’ side frame rail. There are 2 steel lines, the top line (smaller of the 2 lines) is for fuel return to the tank, the bottom line is the fuel supply line (see Figure 1) and is the larger of the 2 lines.
STEP 1:
Cut and remove a section of the fuel supply line; approximately 6 inches will be enough. Use a flaring tool on both ends; this will help keep the fuel hose on the line.
STEP 2:
Next you need to mount the Racor unit. The unit will be mounted by the hood hinge on the drivers’ side (see Figure 2) where there are 2 empty holes. Using the provided nuts, bolts, and washers, mount the Racor unit.
STEP 3:
Install the provided brass elbows into the Racor unit. Use Teflon thread sealant on the threads before installing. Thread one elbow into one of the inlet ports and thread the second elbow into one of the outlet ports. Tighten elbows so the barbs on them both point down.
STEP 4:
Connect one end of the provided rubber fuel line to the fuel supply line that is coming from the tank. Install the provided hose clamp and tighten. Route the fuel line up to the Racor unit inlet port, leaving a little bit of slack in the line and cut the line. Connect the end of the rubber line that you just cut to the brass elbow that is in the inlet port of Racor unit. Secure the hose to the Racor unit with one of the hose clamps. Using the rest of the supplied rubber fuel line, connect one end to the brass elbow that is located on the outlet port of the Racor unit and secure with one of the hose clamps. Route the rubber fuel line down towards the frame and connect it to the open end of the metal fuel supply line and secure with hose clamp (see Figure 3).
STEP 5:
To prime the fuel system, unscrew the Racor filter from the filter head. Fill the filter with clean diesel fuel and re-install on the filter head and tighten. Start the vehicle and run for a few minutes to purge the fuel system of any air and check for leaks.
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