yo Grizz, As the guys advised;
This from 1996 F-150, F-250, F-350, F-Super Duty and Bronco with Gasoline Engines Workshop Manual (PARTIAL)
Same as most earlier years exc. for OBD II in 96, 4WABS (93-96); ABS (87-92); Air Bag (94-96); 3 ***** Automatic Locking Hubs (Built from May 95 through 96); Spark Plug Wire Routing & Firing Order (The firing order for 1987-1993 5.0Ls is 1-5-4-2-6-3-7-8. The firing order for 1994- 96 5.0Ls & all 5.8Ls is 1-3-7-2-6-5-4-8.);
2-piece Spindle Rolling Diaphragm Seal (RDS) used on 5/95 to 96 Broncos & F Series 1/2-ton 4WD
and a few other items that I still need to research
http://www.diesel-dave.com/vehic/manual/stj/stjleft.htm
Section 10-01A: Fuel Tank, Filters, Tubes and Electric Fuel Pump, Gasoline Engines
http://www.diesel-dave.com/vehic/manual/stj/stja1a01.htm
DESCRIPTION AND OPERATION
Fuel Injected Engines
WARNING: TANK-TO-INJECTOR FUEL INJECTION SUPPLY MANIFOLD REMAIN UNDER HIGH PRESSURE AFTER THE SYSTEM IS SHUT OFF. DEPRESSURIZE THE FUEL INJECTION SUPPLY MANIFOLD AT THE SCHRADER VALVE LOCATED ON THE ENGINE FUEL INJECTION SUPPLY MANIFOLD RAIL BEFORE DISCONNECTING ANY FUEL TUBE. DISCONNECTING FUEL TUBES WITHOUT DEPRESSURIZING THE SYSTEM AS DESCRIBED IN THIS SECTION CAN RESULT IN INJURY FROM FUEL BEING SPRAYED UNDER PRESSURE. ALSO, FUEL SPRAYED UNDER PRESSURE IS AN OBVIOUS FIRE HAZARD.
F-Series and Bronco vehicles are equipped with multiport fuel injection (MFI) engines (6007). Separate electronically controlled fuel injectors (9F593) are mounted in the intake manifold (9424) on the runner for each cylinder.
Each fuel injector is mounted so that it sprays fuel into the cylinder head intake port of its cylinder. The fuel injectors are supplied fuel under high pressure through an engine-mounted fuel injection supply manifold (9F792) which also has a fuel pressure regulator (9C968). The fuel pressure regulator controls the pressure of fuel going into the fuel injectors and returns excess fuel to the fuel tanks (9002).
For a description of the operation of the fuel injectors and fuel injection supply manifold, refer to Section 03-04A for 4.9L, Section 03-04B for 5.0L and 5.8L, or Section 03-04C for 7.5L.
On all vehicles, a fuel pump (9350) located in a fuel delivery module (FDM) in the fuel tank supplies fuel under high pressure to the fuel injection supply manifold.
All vehicles have an in-line fuel filter (9155) mounted on the frame rail under the vehicle.
Check (EZiest FIRST):
Fuel Tank Filler Cap; rubber seal may be cracked/damaged; if so, buy new Cap With tether @ Ford dealer or via Amazon)
Fuel Tank for Leaks; underneath or atop skid plat and rolling down around skid plate
tank leaks also from fill hoses as stated and from evaporative emission valve centrally located on the upper surface of the fuel tank and is installed using a rubber gasket seal.
in-line fuel filter mounted on the frame rail under the vehicle; under driver's seat
Fuel and Vapor Return Tubes from tank to filter and Fuel Pressure Regulator 0n driver side rail near firewall to injectors via fuel rail and pressure test Schrader valve on driver side rail
Fuel Pressure Regulator;
Pull the vacuum line on the FPR- any gas aroma or gas inside line, Replace FPR because its diaphragm is ruptured. if needed
Is attached to the fuel injection supply manifold downstream of the fuel injectors. It regulates the fuel pressure supplied to the fuel injectors. The fuel pressure regulator is a diaphragm-operated relief valve in which one side of the diaphragm senses fuel pressure and the other side is subjected to intake manifold vacuum. The nominal fuel pressure is established by a spring preload applied to the diaphragm. Balancing one side of the diaphragm with manifold pressure maintains a constant fuel pressure drop across the fuel injectors. Fuel in excess of that used by the engine is bypassed through the fuel pressure regulator and returns to the fuel tank (9002).
see diagram and more @
http://www.diesel-dave.com/vehic/manual/stj/stj34b08.htm
FPR, Injector & Rail pic
Source: by SeattleFSB (Seattle FSB)
fuel pressure regulator Replacement pics in a 94
Source: by 1994xlt (Cole R
Filter; Diagrams; Read More; Steve also shows Collar/clamshell tools
Source: by Steve
http://www.supermotors.net/clubs/superford/registry/2742/12737
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94 FUEL PRESSURE
ENGINE RUNNING 30-45 PSI KEY ON,
ENGINE OFF 35-45 PSI
Note: Maximum fuel pressure is obtainable at WOT or the vacuum hose removed from the fuel pressure regulator.
Also, Is Check Engine Light ON while driving?
Nevertheless, Try a Self Test for Diagnostic Trouble Codes (DTC)s by my pal, BroncoJoe19
http://broncozone.com/topic/14269-code-reader/?pid=74587&mode=threaded
A helper is good to assist in reading Codes; best is to take a cell fone vid and replay it.
Some basics;
Visual Check
Battery is fully charged & connectors and grounds are clean
Inspect the air cleaner and inlet ducting.