Aeromotive 17130 - 86-98.5 A1000 5.0L MUSTANG STEALTH FUEL SYSTEM - Manual (Page 7)

Section 2 – Fuel Rail Installation
Note:
Please note, due to the wide range of applications and varying OEM and after market component tolerances it has
been found in a few isolated cases where it is necessary to install a 3/8” thick spacer between the upper and lower
intake manifolds. This will allow you to gain clearance between the top of the fuel rails and the bottom of the upper
intake manifold. These spacers are readily available from your local speed shop or mail order warehouse. Also,
94-95 Mustang 5.0L engines have extremely tight clearance between the fuel rail and distributor and may require the
use of an aftermarket distributor such as MSD 8455 to allow clearance for larger, high-flow fuel rails.
2-1. In the vehicles engine compartment, locate a suitable mounting location for the supplied fuel pressure regulator.
2-2. Starting from the decided regulator mounting location in the engine compartment, plan a route to run an AN-08 return
line back to the short return hose hooked to the fuel pump and measure the required length. Cut the return line and
install one AN-08 90-degree hose end on the regulator end of the line and one AN-08 straight hose end on the fuel
tank end of the line, as detailed in Section 4.
Note: Be sure to route all fuel lines clear of any moving suspension or drivetrain components and any exhaust
components! Protect fuel lines from abrasion and road obstructions or debris.
2-3. Thread the 90-degree hose end side of the AN-06 return line onto the AN-06 return port fitting located on the
Aeromotive regulator, and tighten. Use the 15602 (AN-06 union flare fitting) to connect the two straight AN-06 lines
together at the rear of the car, near the tank.
2-4. Remove the air intake ducting from the throttle body and position it out of the way.
2-5. Note the location of, and remove any vacuum lines connected to the upper intake manifold and position them out of
the way.
2-6. Remove the throttle cable from the throttle body; referring to the appropriate vehicle service manual for the procedure
for doing so.
2-7. Unplug the TPS sensor, which is typically located on top of the throttle body.
2-8. Remove the nameplate on the top of the upper intake manifold by removing 4 screws.
2-9. Remove the upper intake manifold bolts (typically, there are 6 of them).
2-10. Gently remove the upper intake from the engine. Place clean shop towels into or tape up the lower intake ports to
prevent any material from entering the intake.
2-11. Carefully clean the old gasket material from both manifolds, while preventing any debris from entering the intake
manifold ports.
2-12. Check for any dirt or debris around the fuel injectors. If any is evident, wash it off with some solvent parts cleaner or
wipe it off with a clean shop towel.
2-13. Disconnect the electrical connector at each injector, making note of the location of each.
2-14. Disconnect both the supply and return fuel lines from the OEM fuel rails. These lines are attached by a special quick
disconnect fitting which requires a special tool for removal. Place clean shop towels around the open fuel lines to catch
any gasoline that may drip out and to prevent any dirt from entering the fuel lines.
2-15. Remove the vacuum line from the fuel pressure regulator.
2-16. Remove the bolts that attach the fuel rail to the lower intake (typically, there are 4 of them).
2-17. Place clean shop towels around the injectors to catch any gasoline that may have spilled during their removal.
Remove the injectors from the manifold by gently pulling upward on the fuel rail / injector assembly. Keep all injectors
connected to the fuel rails. If an injector does pull out of the fuel rail, it may spill a large amount of fuel.
2-18. Carefully remove the fuel injectors from the fuel rail.