Edelbrock Russell 641540 Installation Instructions Manual

©

2007 Edelbrock Corporation

Brochure No. 63-641540

Catalog #641540

Rev. 10/07 - AJ/mc

Page 1 of 5

RUSSELL FORD 5.0L COMPLETE EFI

PLUMBING KIT

Catalog #641540

INSTALLATION INSTRUCTIONS

Please study these instructions carefully before installing your new complete fuel system kit. If you have any questions, please call
our Technical Hotline at: 1-800-416-8628, 7:00 am to 5:00 pm, Monday - Friday, Pacific Standard Time or e-mail us at

[e-mail].

❑ 1 Edelbrock Fuel Pump #1790
❑ 1 Edelbrock Fuel Pressure Regulator Kit #1728
❑ 1 Edelbrock Electric Fuel Pump Relay Kit #1795
❑ 2 Russell 3/8” NPT x -6 AN male adapter
❑ 2 Russell 3/8” NPT x -8 AN male adapter
❑ 1 Mustang 5.0 Fuel Rail Kit
❑ 2 -8 AN black dry sump union
❑ 3 -6 AN black dry sump union
❑ 12 Tie wraps
❑ 1 10 Micron fuel filter, -10 AN I/O
❑ 1 Billet Y-block -10 AN inlet, -8 AN outlets
❑ 5 -10 AN straight x -8 flare reducer
❑ 1 0-100 psi fuel pressure gauge

TOOLS & SUPPLIES RECOMMENDED

❑ Basic hand tools ❑ AN Wrenches
❑ Miscellaneous hardware for mounting components ❑ EFI Fuel line disconnect tool
❑ Drill motor & bits ❑ Multimeter or test light
❑ Wire crimpers or soldering equipment ❑ Wire strippers
❑ Extra wire (Red & Black, 12 gauge & 18 gauge) ❑ Wire terminals & connectors
❑ 10A inline fuse ❑ Assorted nuts & bolts

❑ 1 Russell assembly lube/sealant
❑ 20 ft. Russell -8 hose
❑ 20 ft. Russell -6 hose
❑ 10 Russell -6 cushion clamps
❑ 10 Russell -8 cushion clamps
❑ 3 -6 AN Straight hose end
❑ 4 -8 AN Straight hose end
❑ 1 -6 AN 45° Swivel hose end
❑ 2 -8 AN 45° Swivel hose end
❑ 2 -6 90° Swivel hose end
❑ 4 -8 90° Swivel hose end
❑ 10 ft. Russell 3/16” Wrap-It wire protective sleeve
❑ 10 ft. Russell 5/16” Wrap-It wire protective sleeve

KIT CONTENTS

WARNING!
Gasoline and gasoline fumes are extremely flammable. Work in a well-ventilated area away from open flames,
sparks, or other sources of ignition. Try to contain gasoline when connections are loosened, and clean up any
spills immediately. Failure to do so can result in a fire or explosion.

IMPORTANT NOTE:

Proper installation is the responsibility of the installer. Improper installation will void warranty and may result in

poor performance and engine or vehicle damage.

©

2007 Edelbrock Corporation

Brochure No. 63-641540

Catalog #641540

Rev. 10/07 - AJ/mc

Page 2 of 5

BEFORE BEGINNING

Someone who has a basic knowledge of automobile repair and modification and is familiar with and comfortable with working on
their vehicle can accomplish the mechanical installation of this kit using common tools and procedures. However, this kit is designed
to allow you to custom fit the fuel lines and components to your application, and will require that you cut hoses to fit and drill holes
for fuel pressure regulator mounting, junction blocks, etc. If you do not feel comfortable with any of the steps listed below, please
consult a qualified professional installer. Make sure to read the instructions provided with the supplied fuel rail and fuel pressure
regulator. These will be referenced throughout this instruction sheet.

WARNING:

MAKE SURE TO DISCONNECT YOUR BATTERY TO AVOID THE POTENTIAL FOR SPARKS IN THE WORK AREA!

SOME PROCEDURES IN THIS INSTALLATION WILL REQUIRE THE VEHICLE TO BE RAISED ON JACKSTANDS OR A LIFT. WHEN

RAISING A VEHICLE, MAKE SURE THE VEHICLE IS ON LEVEL GROUND AND SUPPORTED SECURELY BY JACKSTANDS.

NEVER WORK UNDER A VEHICLE THAT IS SUPPORTED BY A JACK ONLY!

AFTER INSTALLATION, BEFORE STARTING THE VEHICLE: ALWAYS make sure to check for any leaks BEFORE starting the

vehicle. Reconnect the battery and turn the ignition key to the “ON“ position. This will activate the fuel pump and pressurize the
fuel system. If any leaks are present, turn the ignition “OFF”, disconnect the battery, and make the necessary corrections before
continuing.

Stock fuel rail disassembly:

1. Make sure the vehicle is on level ground, and the gear
selector is in park or 1st gear. Set the parking brake or
chock the wheels.

2. Make sure that the vehicle has cooled down.

3. Disconnect the negative terminal on the battery.

4. Thoroughly clean the area surrounding the fuel
injectors and the fuel rail. This will prevent debris from
entering the fuel system or the intake manifold upon
fuel rail/injector removal.

5. Relieve residual fuel pressure in the fuel system.
Remove the dust cap cover over the Schrader valve
located on the fuel tube leading to the rail. Hold a shop
towel or rag around the valve while relieving the fuel
pressure to prevent any fuel spray.

6. Using the EFI coupling release tool, disconnect the fuel
feed and return lines. Use a shop towel or rag to catch
any residual fuel remaining in the factory lines.

7. Remove the bolts holding the fuel rail to the intake
manifold.

MUSTANG 5.0 COMPLETE FUEL SYSTEM KIT

8. Remove the fuel regulator, vacuum hose, fuel rail, and
the fuel injectors.

9. Inspect and replace the fuel injector o-rings if
necessary.

10. You will also need to remove the remaining fuel hard
tube (feed and return) running from the fuel rail to the
lower firewall.

Fuel tank removal:

Note:

Use caution when lowering the fuel tank, as some fuel
will be remaining in the fuel tank. These instructions
have been written with the intent of the installer using
a fuel tank or cell equipped with a sump.

1. Drain the fuel from the fuel tank.

2. Raise vehicle using a vehicle lift or by using a jack and
jack stands, if necessary.

3. Remove the fuel tank. Make sure to disconnect all
fittings and wires attached to the fuel tank.