Aeromotive 11109 INSTALLATION INSTRUCTIONS

AEROMOTIVE

Part # 17103

83-93 Mustang 5.0L Fuel System Kit

INSTALLATION INSTRUCTIONS

CAUTION:

Installation of this product requires detailed knowledge of automotive systems and
repair procedures. We recommend that this installation be carried out by a qualified
automotive technician.

Installation of this product requires handling of gasoline. Ensure you are working in a
well ventilated area with an approved fire extinguisher nearby. Extinguish all open flames,
prohibit smoking and eliminate all sources of ignition in the area of the vehicle before
proceeding with the installation.

When installing this product, wear eye goggles and other safety apparel as needed to
protect yourself from debris and sprayed gasoline.

WARNING!

The fuel system is under pressure. Do not open the fuel system until the pressure has
been relieved. Refer to the appropriate vehicle service manual for the procedure and
precautions for relieving the fuel system pressure.

Aeromotive system components are not legal for sale or use on emission controlled motor vehicles.

This kit contains the following parts

1 ea fuel tank kit
1 ea fuel tank w/sump
1 ea return line fitting
1 ea fuel pump wiring kit
1 ea 3ft length of 10 ga. Black wire
1 ea 25ft length of 10 ga. Red wire
1 ea 30 amp circuit breaker
1 ea 30 amp automotive relay
2 ea blue female blade connector
2 ea yellow female blade connector
5 ea yellow #10 stud ring connector
1 ea yellow 3/8” stud ring connector
6 ea tie-wraps
4 ft AN-10 stainless steel braided line
14 ft AN-06 stainless steel braided line

Warning – The included Aeromotive fuel pump is not compatible with alcohol based fuels or

fuel additives!

:

1 ea AN-06 straight hose end
3 ea AN-06 90-degree hose end
2 ea AN-10 90-degree hose end
1 ea p/n 11101 Pump
1 ea p/n 12304 Filter 100 Micron SS
1 ea p/n 12301 Filter 10 Micron Paper
4 ea ¼” flat washers
4 ea ¼-20 nyloc nuts
4 ea ¼-20 x 1” carriage bolts
12 ea tie-wraps
9 ea AN-10 o-ring
1 ea p/n 15101 Return line adapter
1 ea p/n 15103 supply line adapter
4 ea p/n 15608 AN-10 cutoff union
2 ea p/n 15609 AN-10 cutoff to AN-06 union
1 ea p/n 15617 AN-10 port plug

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The following steps are typical of most installations:

Section 1 - Fuel system installation

Section 2 – Fuel line hose end installation

Section 3 – Electrical Installation

Section 4 – Final checks and system start-up

Fuel Pump Template

Typical hose end to fitting connection:

Do not connect hose end to cutoff side of union!

Connect hose end to 37-degree flare side of union.

Typical o-ring sealed port connection:

O-ring sealed AN style port

O-ring

(Install on union fitting between back o

threads and face of hex nut.)

Hose End

Typically the cutoff side of the union is used as
the o-ring sealed side, leaving the 37-degree
flare side for your hose end connection. In some
cases both sides of the union utilize an o-ring
seal. For example, in this kit a union connects
the both ports of the fuel pump and filter.

Section 1 - Fuel system installation:

1-1. Once the engine has been allowed to cool, disconnect the negative battery cable and relieve the fuel system

pressure.

1-2. Raise the vehicle and support it with jack stands.

1-3. Referring to the appropriate vehicle service manual for instructions, drain, disconnect any electrical and fuel

component connections and remove the OEM fuel tank. The removal of the vehicles exhaust system may be
necessary for fuel tank removal.

1-4. Once the OEM fuel tank has been removed, remove the plastic fuel tank shield from the bottom of the tank.

1-5. Measure the position of the sump on the supplied Aeromotive fuel tank and mark the plastic fuel tank shield

accordingly. Using an ½” drill bit, drill the four corners of the sump cutout in the plastic fuel tank shield. Using a small
hand saw or reciprocating saw, cut out the remaining area from the plastic fuel tank shield. Once you have completed
this step your plastic fuel tank shield should look similar to Figure 1-1.

Figure 1-1

1-6. In the kit find two AN-10 cutoff union fittings and four of the AN-10 o-rings. Install each of the four o-rings on each end

of the two AN-10 cutoff union fittings.

1-7. Install each of the two AN-10 cutoff fittings into each end of the provided Aeromotive fuel pump, Aeromotive p/n

11101.

1-8. Noting the appropriate flow directions, install the provided fuel filter, Aeromotive p/n 12301, on the fuel pump outlet

and the other fuel filter, Aeromotive p/n 12304, on the fuel pump inlet. See figure 1-2.

Figure 1-2

1-9. Install one of the supplied AN-10 o-rings on the cutoff side of the AN-10 cutoff union fitting, if not already installed,

A

and install on the inlet side of the pump / filter assembly as shown in figure 1-3.

1-10. Install one of the supplied AN-10 o-rings on the AN-10 cutoff side of the AN-10 cutoff to AN-06 reducer union fitting,

if not already installed, and install on the outlet side of the pump / filter assembly as shown in figure 1-3

1-11. Position the fuel pump / filter assembly from above on the opposite end of the plastic fuel tank shield as the sump

cutout. Center the pump / filter assembly in all directions on the flat shown in figure 1-3. Using the fuel pump as a
guide, mark the four pump mounting holes. Insure there are no obstructions behind the plastic fuel tank shield and
drill four ¼” mounting holes.

1-12. The fuel pump should be installed such that when the plastic fuel tank shield is installed the fuel pump outlet is on

the driver side of the vehicle. Secure the fuel pump to the plastic fuel tank shield by installing each of the four ¼”
carriage bolts from the inside of the fuel tank shield, through the fuel tank shield and through the fuel pump mounting
holes. Install each of the four provided flat washers and nuts on the bolts and tighten. The plastic fuel tank shield now
should look similar to the one shown in figure 1-3.

Outlet of pump

Inlet

Cutout for sump

Figure 1-3

1-13. Inspect the inside of the plastic fuel tank shield for any sharp edges that could puncture the fuel tank. If any sharp

edges are found, correct before proceeding.

1-14. Position the plastic fuel tank shield on the Aeromotive fuel tank.

AN-10 Return Line Port

N-10 Outlet Ports

Figure 1-4

1-15. Install one of the supplied AN-10 o-rings on the cutoff side of the AN-10 cutoff union fitting, if not already installed,

and install on the passenger (right) side of the fuel tank sump.

1-16. Install one of the supplied AN-10 o-rings on the AN-10 port plug, if not already installed, and install on the driver

(left) side of the fuel tank sump.