Bbk-performance 5015 User Manual download pdf

INS 140

1996-98 MUSTANG 4.6L 2-V

FUEL RAIL KIT

PART# 5015

NOTE- 1998 Mustang will require the purchase of (1) BBK 1707 or equivalent

fuel pressure regulator.

Warning!

Fuel system is under pressure. You will need to relieve this pressure in Step

4. Please read instructions carefully!

Tools required-

1/2”& 5/8” Spring-Lok type fuel line disconnect tools, 11/16” wrench, 12, 10, & 8mm sockets,

5mm & 5/32” Allen wrenches. Lithium grease, Teflon tape, Anti seize.

Step 1

Disconnect negative battery terminal.

Step 2

Remove 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 piece.

Step 3

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 than gasoline itself.

Step 4

Hold a rag around the shrader valve on the front of the passenger side rail, and then

bleed off any fuel pressure by depressing the valve with a small screwdriver or pick

tool.

Step 5

Unplug the electrical connections from the fuel injectors and fuel pressure sensor

(99-04).

Step 6

Using 1/2” and 5/8” Spring Lok removal tools, disconnect fuel feed and return lines

from the fuel rails.

Step 7

Use an 8mm socket to remove the studs that attach the fuel rails to the intake

manifold.

Step 8

Remove the fuel rails and injectors.

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.

Step 9

Apply a touch of white grease to all of the supplied O-rings and to the O-rings on the

fuel injectors.

Step 10

Place (1) O-ring over the ends of the (2) rail end caps, the (2) rail end adapters, and

the (1) 5/8” Spring Lok fitting. The remaining O-ring is a spare since the O-rings are

thin and delicate BBK has supplied (1) extra.

Step 11

For both rails, install an end cap on the front of the rail and a -6 rail end adapter on

the rear of each rail and attach the rail mounting tabs with the supplied 1/4”-20 bolts.

NOTE

Each rail mounting tab has a round hole and a slotted hole. The round holes

will attach the rails. The slotted holes will attach to the intake manifold.

1 2 3

Summary of Contents

Page 1 - Warning!

INS 140 1996-98 MUSTANG 4.6L 2-V FUEL RAIL KIT PART# 5015 NOTE- 1998 Mustang will require the purchase of (1) BBK 1707 or equivalent fuel pressure

Page 2

Step 12 Install supplied Spring Lok fitting into the side of the passenger rail. Step 13 Insert (4) injectors into the passenger side rail. Step 14 In

Page 3

5015 Bill Of Materials (1) Driver side rail (1) Passenger Side Rail (2) 10-32 x 3/4” SHCS (2) 10-32 x 3/8” SHCS (4) 1/4”-20 x 3/8” BHCS (4) M6x1.0x16

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