1999-2004 Ford Mustang 4.6L 2-V
INS-128
Special Tools
Install Time:
Difficulty:
STEP 1
STEP 4
• Disconnect the negative battery terminal.
together as one.
STEP 3
STEP 2
• Hold a rag around the Schrader valve on the
with a small flat head screwdriver or pick tool.
• Disconnect the throttle cables, unplug the
flammable then gasoline itself.
• Unplug the electrical connections from the fuel
STEP 5
• Apply a touch of white grease to all of the
the groove closest to the sensor head.
Fuel Rail Kit
Part #5016
Required:
1/2” & 5/8” Spring-
•
Lok type fuel
disconnect tools
White Lithium Grease
•
Teflon Tape
•
Follow these instructions carefully to ensure correct fitment and operation.
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
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
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.
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
Approximately
2 Hour
3 out of 5
front of the driver side fuel rail, and then bleed
off any fuel pressure be depressing the valve
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INS-128
STEP 6
STEP 9
• For both rails, install an end cap on the front of
intake manifold end and fuel rail mount tabs.
STEP 7
• Install the supplied Spring Lok fitting into the
• Install the original fuel pressure sensor onto the
STEP 10
STEP 8
• Insert (4) injectors into the driver side rail. Install
manifold by using the supplied hardware.
• Install the passenger side rail and injectors by
STEP 12
STEP 11
• Route the stock fuel feed line under the A/C line
• Assemble the cross over hose by pushing the
contact is made with the EGR Tube.
1999-2004 Ford Mustang 4.6L 2-V
Fuel Rail Kit
Part #5016
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
side of the passenger rail. Insert (4) injectors
into the passenger side rail.
guiding the tip of each injector into its respective
bung in the intake manifold. Secure the rail to
the intake manifold using the supplied
hardware. NOTE!!! To ensure clearance
between the fuel rails and ignition coils, use
(1) of the supplied washers under the
mounting tabs and place (1) over the
threaded portion of each bolt that go
through the tabs at the intake manifold.
NOTE!!! Take extreme care when installing
the small button head cap screws (BHCS)
into the fuel rail. Using the wrong length will
penetrate the fuel rail resulting in a fuel leak.
Use the supplied washers underneath the
small BHCS’s. In addition these screws can
easily cross thread.
driver side fuel rail with supplied o-ring and the
supplied 10-32x1/4” BHCS’s. NOTE!!! Measure
these screws from the bottom of the head to
the end first to ensure you are using the
correct hardware here!
the driver side fuel rail and injectors by guiding
the tip of each injector into its respective bung in
the intake manifold. Secure the rail to the intake
barbed ends of the supplied 90 degree fittings
into the end of the hose. Tighten the cross over
hose onto the threads of the rail end adaptors
on the back of both rails. NOTE!!! When
routing the cross over hose, be mindful of
hot EGR tube it must pass by. Route so no
and connect to the 5/8” Spring Lok fitting on the
side of the passenger side fuel rail.
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