AEROMOTIVE Part # 17103 83-93 Mustang 5.0L Fuel
Contents
1. 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 7 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 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 fil2. 80 psi 6 7 Once the desired fuel pressure is achieved tighten the regulator adjustment jam nut and attach the vacuum line 6 8 Remove the fuel pressure gauge and replace the cover on the schrader valve 6 9 Test drive the car to insure proper operation and re check the fuel system for leaks If any leaks are found immediately discontinue use of the vehicle and repair the leak s Thanks for purchasing another quality product designed engineered and manufactured in Kansas City USA AEROMOTIVE INC 7805 Barton Street Lenexa KS 66214 913 647 7300 fax 913 647 7207 SLIOS of T Lddoow OL SATOH b TITY AEROMOTIVE INC LIMITED WARRANTY This Aeromotive Product with proof of purchase dated on or after January 1 2003 is warranted to be free from defects in materials and workmanship for a period of one year from the original date of purchase No warranty claim will be valid without authentic dated proof of purchase This warranty is to the original retail purchaser and none other and is available directly from Aeromotive and not through any point of distribution or purchase If a defect is suspected the retail purchaser must contact Aeromotive directly to discuss the problem possible solutions and obtain a Return Goods Authorization RGA if deemed necessary by the company Please call 913 647 7300 and dial option 3 for the technical service dept All returns must be shipped freight pre paid to the company and with valid RGA be
3. and work the filler neck in to the grommet on the side of the fuel tank Once the Aeromotive fuel tank is in position align tank straps ensure that there are not any hoses or wiring pinched and tighten the strap bolts 1 31 Make any line or electrical adjustments necessary to clear the vehicles exhaust suspension and drivetrain components 1 32 Under the car just in front of the fuel tank locate the OEM supply line quick disconnect coupler This is the same quick disconnect coupler that you disconnected to remove the OEM fuel supply line from the OEM fuel tank Locate the supplied adapter fitting that adapts the quick disconnect fitting to an AN 06 fitting Apply a light oil to the surface of the supplied adapter fitting and install this will allow you to connect an AN 06 supply line to the OEM fuel line 1 33 Using the two remaining supplied AN 06 hose ends as a guide measure the length of line needed to connect the outlet of the pump filter assembly to the adapter fitting that you just installed into the OEM supply line Figure 1 7 shows a typical installation 1 34 Using the remaining AN 06 steel braided hose cut and assemble the steel braided hose and hose ends as shown in Section 2 1 35 Thread the straight side of the AN 06 supply line that you have just created onto the above adapter fitting and tighten Thread the 90 degree side of the AN 06 supply line on the AN 06 fitting that you installed earlier on the pump filter as
4. return and fuel level sender are secure Apply a light oil weight oil to the filler neck grommet to ease installation 1 26 In the front of the vehicle near the right wheel well find the OEM return line quick disconnect coupler Disconnect this coupler and install the supplied adapter fitting this will allow you to run an AN 06 return line back to the fuel tank 1 27 Starting from the above mentioned adapter fitting plan a route to run an AN 06 return line back to the Aeromotive fuel tank return port and measure the required length Cut the return line to the determined length and install two of the supplied AN 06 90 degree AN 06 hose ends as detailed in section 2 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 1 28 Thread one 90 degree side of the AN 06 return line that you have just created onto the adapter fitting installed in the front of the vehicle and tighten Using the supplied tie wraps secure the return line to the vehicle in the route you have chosen ensuring that all lines are routed clear of any suspension drivetrain and exhaust components 1 29 Thread the other 90 degree end of the AN 06 return line onto the AN 06 return port fitting located on the Aeromotive sump and tighten 1 30 As the Aeromotive fuel tank is lifted into position reattach the vent line to the top of the fuel tank
5. AEROMOTIVE Part 17103 ra 83 93 Mustang 5 0L Fuel System Kit AEROMOTIVE 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 AN 06 straight hose end 1 ea fuel tank w sump 3 ea AN 06 90 degree hose end 1 ea return line fitting 2 ea AN 10 90 degree hose end 1 ea fuel pump wiring kit 1 ea p n 11101 Pump 1 ea 3ft length of 10 ga Black wire 1 ea p n 12304 Filter 100 Micron SS 1 ea 25ft length of 10 ga Red wire 1 ea p n 12301 Filter 10 Micron
6. Paper 1 ea 30 amp circuit breaker 4 ea 4 flat washers 1 ea 30 amp automotive relay 4 ea 20 nyloc nuts 2 ea blue female blade connector 4 ea 4 20 x 1 carriage bolts 2 ea yellow female blade connector 12 ea tie wraps 5 ea yellow 10 stud ring connector 9 ea AN 10 o ring 1 ea yellow 3 8 stud ring connector 1 ea p n 15101 Return line adapter 6 ea tie wraps 1 ea p n 15103 supply line adapter 4 ft AN 10 stainless steel braided line 4 ea p n 15608 AN 10 cutoff union 14 ft AN 06 stainless steel braided line 2 ea p n 15609 AN 10 cutoff to AN 06 union 1 ea p n 15617 AN 10 port plug Warning The included Aeromotive fuel pump is not compatible with alcohol based fuels or fuel additives 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 Hose End Typical o ring sealed port connection O ring sealed AN style port O ring Install on union fitting between back of threads and face of hex nut 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
7. fore they will be processed Aeromotive will examine any product returned with the proper authorization to determine if the failure resulted from a defect or from abuse improper installation misapplication or alteration Aeromotive will then at it s sole discretion return repair or replace the product If any Aeromotive product is determined defective buyer s exclusive remedy is limited in value to the sale price of the good In no event shall Aeromotive be liable for incidental or consequential damages Aeromotive expressly retains the right to make changes and improvements in any product it manufactures and sells at any time These changes and improvements may be made without notice at any time and without any obligation to change the catalogs or printed materials Aeromotive expressly retains the right to discontinue at any time and without notice any Aeromotive product that it manufactures or sells This warranty is limited and expressly limits any implied warranty to one year from the date of the original retail purchase on all Aeromotive products No person party or corporate entity other than Aeromotive shall have the right to determine whether or not this Limited Warranty is applicable to any Aeromotive product authorize any action whatsoever under the terms and conditions of this Limited Warranty assume any obligation or liability of any nature whatsoever on behalf of Aeromotive under the terms and conditions of this Limited War
8. g each of the four 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 nel V gt lt a v ad _ AN 10 Return Line Port AN 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 1 17 Using the two supplied 90 degree AN 10 hose ends as a guide measure the length of AN 10 steel braided line needed to connect the fuel tank sump outlet to the fuel pump filter assembly inlet 1 18 Cut and assemble the steel braided hose and hose ends as shown in Section 2 1 19 Using the above steel braided hose assembly connect one end to the outlet of the fuel tank sump and the
9. ions or debris 3 5 Connect terminal number 87 on the relay to the positive terminal on the fuel pump This is accomplished by using the supplied red 10 ga wire one of the yellow female blade connectors on the relay side of the wire and one of the yellow 10 ring connectors or appropriate connector for the installation on the fuel pump side of the wire 3 6 Connect the negative terminal on the fuel pump to a clean chassis ground using the supplied black 10 ga wire and two yellow 10 ring connectors 3 7 Connect 12VDC to the circuit breaker using the supplied red wire and one of the yellow 10 ring connectors and the supplied yellow 3 8 ring connector 3 8 Ensure that electrical components and wires are connected properly See Figure 3 1 and are clear of any moving suspension or drivetrain components and any exhaust components Protect wires from abrasion and road obstructions or debris SUPPLIED oe ne 39 AMP RE mnie A WIRE NOT CLEAN CHASSIS 12 VDC FROM OEM T p SUPPLIED GROUND FUEL PUMP o OR RED WIRE eE GROUND FROM OFM ll FUEL PUMP BLK WIRE SUPPLIED RED 10 GA WIRE FUEL PUMP SUPPLIED SUPPLIED 412 VDC RED 19 GA WIRE PLACK 10 GA WIRE CLEAN CHASSIS SUPPLIED 30 AMP GROUND CIRCUIT BREAKER CIRCUIT BREAKER TO BE INSTALLED AS CLOSE TO BATTERY AS POSSIBLE FROM BATTERY Figure 3 1 Section 4 Final Checks and System Start up 6 1 Ensure that any spilled gasoline and any gasoli
10. ne soaked shop towels are cleaned up and removed from the vicinity of the vehicle 6 2 Carefully lower the car onto the ground 6 3 Fill the fuel tank with gasoline and check for any leaks in the system if any leaks are found repair immediately CAUTION While performing the following steps if any fuel leaks are detected immediately turn the ignition of OFF remove any spilled fuel and repair the leak s before proceeding 6 4 Reconnect the battery and turn the ignition to the ON position WITHOUT starting the car After several seconds check the fuel pressure If there is no fuel pressure turn the ignition key to the OFF position wait one minute return the ignition to the ON position and recheck the fuel pressure Repeat this ignition OFF and ON procedure until the fuel pressure gauge registers fuel pressure 6 5 With the fuel pressure gauge registering fuel system pressure check for fuel leaks throughout the entire fuel system If any fuel leaks are found turn the ignition key to the OFF position remove any spilled fuel and repair the leak before proceeding 6 6 Once the fuel pressure gauge registers fuel system pressure and there are no fuel leaks start the engine and adjust the regulator to the desired fuel pressure Turning the adjustment screw clockwise will increase fuel pressure OEM regulators are typically set at approximately 43 psi without the vacuum line attached The fuel pressure adjustment range for this regulator is 35
11. on pressure prior to use Section 3 Electrical Installation 3 1 Find a suitable place to mount the supplied relay the relay is typically mounted by the OEM fuel pump wiring connector Never mount the relay inside of the fuel tank or next to fuel tank vents Insure the relay and any associated parts are clear of the exhaust any moving suspension or drivetrain components and any possible road obstructions or debris 3 2 Attach the OEM fuel pump wires These typically are the red and black wires from the OEM wiring harness going to the fuel tank to relay terminals 85 and 86 using two of the supplied blue female blade connectors See Figure 3 1 Below Note Be sure to route all electrical wires clear of any moving suspension or drivetrain components and any exhaust components Protect wires from abrasion and road obstructions or debris 3 3 Find a suitable location for mounting the supplied circuit breaker For optimal circuit protection the circuit breaker needs to be mounted as close to the battery as possible 3 4 Connect terminal number 30 on the relay to the circuit breaker by using the supplied red 10 ga wire one of the yellow female blade connectors on the relay end of the wire and one of the yellow 10 ring connectors on the circuit breaker side of the wire Note Be sure to route all electrical wires clear of any moving suspension or drivetrain components and any exhaust components Protect wires from abrasion and road obstruct
12. other end to the fuel pump filter assembly inlet and tighten See figure 1 5 Note It is recommended that a fuel shut off valve be installed between the fuel tank outlet and the fuel pump filter assembly inlet these valves are available from most popular racing fitting manufactures Aeroquip Earl s Goodridge Russell etc Figure 1 5 1 20 Using any type of household tape secure the plastic fuel tank shield to the Aeromotive fuel tank along each of the fuel tank strap indentations 1 21 Carefully flip the fuel tank plastic fuel tank shield assembly over 1 22 From the old OEM fuel tank remove the filler neck rubber grommet fuel level sender vent and vent grommet and wiring harness Reinstall each of these components in the new Aeromotive fuel tank while inspecting them for any damage If any of the OEM components are damaged replacement parts are available through your local Ford dealer or auto parts store See figure 1 6 1 23 Remove the OEM fuel pick up from the OEM fuel tank inspect the gasket for any damage Using the OEM gasket install the Aeromotive provided return pick up block off plate in the new Aeromotive fuel tank Figure 1 6 1 24 Install the supplied AN 10 o ring on the AN 10 side of the AN 10 cutoff to AN 06 reducer union if not already installed and install this fitting in the AN 10 return port on the sump 1 25 Position the fuel tank under the vehicle insuring that the retaining rings on the
13. ranty This Limited Warranty covers only the product itself and not the cost of installation or removal This Limited Warranty is in lieu of and expressly excludes any and all other warranties expressed or implied This Limited Warranty gives you specific legal rights and you may also have other rights which vary from state to state Aeromotive Inc 7805 Barton Street Lenexa KS 66214 Phone 913 647 7300 Fax 913 647 7207
14. sembly outlet Ensure that all lines are routed clear of any suspension drivetrain and exhaust components Section 2 Fuel Line Hose End Installation CAUTION When assembling this product wear eye goggles and other safety apparel as needed to protect yourself from debris and sharp edges 2 1 Wrap hose with masking tape at desired cutoff length Cut hose through masking tape squarely to desired length using a cut off machine or a fine tooth hacksaw Remove the masking tape 2 2 Unthread the hose socket from the rest of the hose end fitting 2 3 Insert hose in the socket with a twisting and pushing motion until the hose is fully seated in the socket 2 4 Using a grease pencil marker or tape mark the location of the hose in relation to the hose socket that you just installed 2 5 Using a light oil lubricate the inside of the hose and hose end mating parts 2 6 Carefully thread the hose end onto the hose socket making sure that the hose does not push out of socket by observing the mark you placed on the hose in step 2 4 2 7 Using a properly sized wrench complete threading the two components together The maximum allowable gap between the two fitting components is 030 inches 2 8 Inspect the hose for push out by comparing the mark you made on the hose in step D to the hose end socket location 2 9 Clean all debris from exterior and interior of hose 2 10 All lines should be tested to twice their operati
15. ter 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 er Na ATE VE 2 2 0 ONI ast T A v r iar so WS Ve x v mn gt a A E acts ha at ie RNR PEE OA 3 SO tO te TRA 3 occ ve gt xi Faw se iF s x ba ks meek M Ale k x A ons Sy gt ax O er 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 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 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 installin
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