AUX Fuel tank port fittings on Econoline

[Big_ern_101]

Just wanted to throw this out as an FYI since I couldn't find definitive info anywhere.

I installed the plumbing for my diesel heater yesterday tapping into the OEM aux fuel port on my 2006 E350 Diesel.

How do you know you have an aux fuel port?
-Look at the top of the fuel tank where the sending unit is. There will be one little black cap on an unused line.
-You can also check your window sticker if you still have it or search for the options on your van by VIN.

How do you connect to it?
-Use a 1/4" push connect fuel line with your choice of barb on the exit end. I used 1/4" push connect to 1/8" barbed for my diesel heater. The best fittings for my year is a straight fitting, not a 90 degree.

How do you get to it?
-Maybe if you have elf hands and the patience of a saint you can get to it without dropping the tank. I do not have either of those qualities.
-Support the tank with a transmission jack. Can be pretty full since you are not dropping it all the way. I put two 2 foot 2x4s on top of my jack to distribute the load.
-Remove both straps, disconnect the fuel pump sending unit wiring, the fill line, and the vent line. Fuel lines can stay connected.
-Drop the tank down about 8", that was enough for me to have plenty of access.
-Installation is reverse of removal as they say. Get the fuel fill and vent and wiring reconnected before bringing the tank all the way up.
-I had to loosen my straps and shift the tank close to the frame to get the fill and vent fully connected.

Happy trails!

 

[posplayr]

FYI this is the fitting if you have the aux port in your sending unit (for my 2011 so probably 08+). If not you can buy them aftermarket or pop for the Motorcraft unit.

This is the fuel pump assembly with aux port I got for the 2011 Flex fuel
DELPHI FG1479 (Daily Driver) Module Assembly (Rock Auto)

I bought a

2011 Genuine Ford Auxiliary Outlet 9C2Z-9B210-A

https://www.ebay.com/itm/403446441012

https://www.fordpartsgiant.com/parts/ford-kit_9c2z-9b210-a.html

 

[Big_ern_101]

The 90 degree OEM fittings are for the later vans that have vertical outlets on the fuel tanks. On a 2006 the fuel tank outlets already have a 90 degree bend on the sending unit side, so you need a straight fitting to connect to it or the routing is going to be all screwy. I have not seen an OEM part number for a 1/4" push connect to straight barbed fitting that would be applicable in my 2006 van.

For a diesel heater, the bigger fittings would have also needed a reducer. The 1/4" push lock to 1/8" barbed was a perfect match.

 

[Vanimal]

Pics would be great. My 46 gallon tank is a bear to drop just to check and find out their is none.

 

[Big_ern_101]

You can see the aux fitting without dropping the fuel tank. Stick your melon up between the body of the van and the outside of the framerail to the LH side of the fuel filler (toward rear tire)
Look where the fuel and vent lines enter the tank, if you have an aux connection you will see a capped off line that goes to nowhere.

Easy button is to check your VIN and see if the aux fuel tap was an option.

 

[capnjim-SMB]

Two questions:

How do you get the black cap off the unused port?

Do you have a part number for the snap to connect 1/4 to 1/8 straight fitting.

I’m in the process of installing a similar heater in my 2006 6.0 PSD van.

I appreciate any help.

 

[Big_ern_101]

Getting the black cap off
-I had to drop my tank down part way to get both hands up there, then you squeeze the little "squares" in and at the same time pull the cap off the unused port. Once the cap is off, there is a plastic lock tab that can be split open and pulled off the tube.

Fitting
https://www.amazon.com/Quick-Connec...line+wuick+connect+to+1/8+barb,aps,103&sr=8-1

 

[capnjim-SMB]

Thank you Big Ern.

 

[kbeefy]

Thanks, I have a diesel heater to install and was curious if it was an option on the Fords. When I get mine on the lift I'll take a look.

 

[Kibo]

If you're truly lazy like me and don't want to drop the fuel tank, you may be able to get away with using a pair of longnose spark plug boot pliers like this.

This was on a later (2011) van with the vertical outlet; the screwdriver was used to pry the ears of the yellow locking piece out of the way, then to pry the plug upwards (between the yellow and black in the photo below) while depressing the lock tabs with the pliers.

Once I had it out and could see what the yellow piece actually looks like, I think you're supposed to just slide it outwards?

 

[seven_o_savage]

I am eternally grateful for you post. I was able to finish my gasoline heater install on my sportsmobile e350 today purely because you decided to share the results.

Here’s how I went about it mine.
1. Remove driveshaft by unbolting 4 bolts at back - note: it’s a 12 point star, 12mm bit. to get more room to get your hands over the tank).
2. Reach hand over top of tank and move yellow piece back
3. Squeeze sides of plug and pull off (2 and 3 took about 2 hours total because you’re going purely by feel and there’s basically 0 room to move your hand around … just had to be persistent keep trying)
4. Attach heater hose to this part from Amazon with included connector & clamps in heater kit https://a.co/d/e04lL6J
5. Attach new line to port


Pretty brutal overall, but far less than dropping the tank! Here are some photos.

 

[1der]

Any info on how far down into the tank the AUX pick up reaches?

 

[Big_ern_101]

Ive ran out of diesel heater fuel at around 1/4 tank indicated on my 2006 with a chopped tank for transfer case clearance. But my fuel gauge doesnt seem to be super accurate.

Next time I drop the tank (hopefully never) I am going to pull the sender and toss an extension on the dip hose because I am not running a high draw device like a generator.

Currently I just follow the best practice of filling up before pulling into camp - always try to stop when I am an hour or less out. That way I know if I am going adventurin', driving around in a convoy, or wanting to run my diesel heater, I have a few hundred miles worth of fuel ready and waiting.

 

[kbeefy]

Any info on how far down into the tank the AUX pick up reaches?

This is on a 2004 6.0 diesel, not sure how similar the other engine and year choices are....

I would guess 50-60% down. I added an extension....

Looking at it now I might not extend it quite so far on the next one. That probably leaves me about 5g, but like @Big_ern_101 I try to park with at least 1/2 tank.

 

[kbeefy]

I am eternally grateful for you post. I was able to finish my gasoline heater install on my sportsmobile e350 today purely because you decided to share the results.

Here’s how I went about it mine.
1. Remove driveshaft by unbolting 4 bolts at back - note: it’s a 12 point star, 12mm bit. to get more room to get your hands over the tank).
2. Reach hand over top of tank and move yellow piece back
3. Squeeze sides of plug and pull off (2 and 3 took about 2 hours total because you’re going purely by feel and there’s basically 0 room to move your hand around … just had to be persistent keep trying)
4. Attach heater hose to this part from Amazon with included connector & clamps in heater kit Amazon.com
5. Attach new line to port


Pretty brutal overall, but far less than dropping the tank! Here are some photos.

I've seen a few of your you tube vids, thanks for sharing!

 

[1der]

Diesel heater = .03G/hr. x 8 hrs overnight = 0.24 gals., which if used for driving gets me 3 miles down the road. I can be stuck for 10 days in one spot and use up far less than three gals of fuel depending on temperatures and I would be warm and survive.

Or, I can have 10 plus gals of fuel (1/4 tank) and be miserable because the pickup for the heater is sucking air. Or, I can pull into a camp spot / rest stop / road closed situation in very cold weather with 1/3rd of a tank and have the heater run out of accessible fuel an hour after I fire it up.

I am putting the pickup to within 1/2" of the bottom of the tank. If I plan so poorly that 1/3rd of a gallon strands me because of inattention, then the two gallons in the Rotopax is my insurance policy.

Note: the Gasoline based heater uses a bit more, but still very frugal.