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1999-2004 Ford Mustang 4.6L 2-V

Fuel Rail Kit

Part #5016

INS-128

Follow these instructions carefully to ensure correct fitment and operation.

Special Tools

Required:

•

1/2” & 5/8” Spring-

Lok type fuel

disconnect tools

•

White Lithium Grease

•

Teflon Tape

Install Time:

Approximately

2 Hour

Difficulty:

3 out of 5

STEP 1

STEP 4

• Disconnect the negative battery terminal.

Remove the air inlet hose assembly from the

throttle body. NOTE!!! The throttle body does

not need to be separated from the plenum

for the next step. You can remove them

together as one.

STEP 3

STEP 2

• Hold a rag around the Schrader valve on the

front of the driver side fuel rail, and then bleed

off any fuel pressure be depressing the valve

with a small flat head screwdriver or pick tool.

• Disconnect the throttle cables, unplug the

sensors and vacuum connections from the

intake plenum (also known as the intake elbow),

unbolt the EGR valve from the driver side and

unbolt and remove the intake plenum assembly.

NOTE!!! In the next step you will release the

fuel pressure in the fuel rails. Be sure to

extinguish any open flames and disable any

spark or ignition sources, or other potential

fire hazards around the work area. Keep in

mind that Gasoline VAPORS are more

flammable then gasoline itself.

• Unplug the electrical connections from the fuel

injectors and fuel pressure sensor. With a 5/8”

Spring Lok removal tool, disconnect the fuel

feed line from the fuel rails. Use an 8mm socket

to remove the bolts that attach the fuel rails to

the intake manifold. Remove the fuel rails and

injectors by simply lifting them straight up.

NOTE!!! Now is the time to inspect your fuel

injector tips and O-Rings. If they are

damaged, replace them. Damaged O-Rings

can cause a fuel leak.

• Remove the fuel pressure sensor from the

driver side fuel rail.

STEP 5

• Apply a touch of white grease to all of the

supplied O-Rings and to the O-Rings on the

Fuel Injectors. Place (1) O-Ring over the ends

of the (2) Rail End Caps, the (2) rail end

adaptors, and the (1) 58” Spring Lok Fitting.

Remove the (2) O-rings from the pressure

switch. Install the (1) supplied small O-Ring into

the groove closest to the sensor head.

Summary of content (3 pages)

PAGE 1
999-2004 Ford Mustang 4.6L 2-V Fuel Rail Kit Part #5016 Special Tools Required: • 1/2” & 5/8” SpringLok type fuel disconnect tools White Lithium Grease Teflon Tape • • Install Time: Approximately 2 Hour Difficulty: 3 out of 5 Follow these instructions carefully to ensure correct fitment and operation. STEP 1 STEP 4 • • Disconnect the negative battery terminal. Remove the air inlet hose assembly from the throttle body.
PAGE 2
1999-2004 Ford Mustang 4.6L 2-V Fuel Rail Kit Part #5016 STEP 6 STEP 9 • • For both rails, install an end cap on the front of the rail and a rail end adaptor on the rear of each rail and attach the rail mounting tabs with the supplied ¼”-20 bolts. NOTE!!! Each Rail mounting tab has a round hole and a slotted hole. The round holes will attach to the rails. The slotted holes will attach to the intake manifold. Use the supplied washers at the intake manifold end and fuel rail mount tabs.
PAGE 3
1999-2004 Ford Mustang 4.6L 2-V Fuel Rail Kit Part #5016 STEP 13 STEP 14 • • Reconnect the negative battery terminal. WITHOUT STARTING THE ENGINE Turn the ignition to the ON position for 3-4 seconds, (primes the fuel system) then OFF 3 times and return to the ON position. Check all connections for fuel leaks. CORRECT ANY LEAKS BEFORE STARTING!!! Re-install the intake elbow and re-attach all connections. Re-install the air inlet tube.