BBK Performance 5016 - Manual

1999-2004 Ford Mustang 4.6L 2-V
Fuel Rail Kit
Part #5016
1
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.