Operating and Installation Instructions This Product is Protected by U.S. Patent 8,388,322 and 7,810,470

Transcription

1 Model Number Ford Mustang GT500 Total Fuel System Package Operating and Installation Instructions This Product is Protected by U.S. Patent 8,388,322 and 7,810,470 CAUTION! This product is to be installed only by persons knowledgeable in the repair and modification of vehicle fuel systems and general vehicle systems modification. Only a qualified technician or mechanic who is aware of applicable safety procedures should perform the installation of this product. GASOLINE AND OTHER FUELS ARE FLAMMABLE AND CAN BE EXPLOSIVE! Perform the installation in a well ventilated location only to minimize the build up of fuel vapors. NO open flames, smoking or other sources of ignition are to be present during installation, to prevent fire or explosion that can cause serious injury or death. Grinding, cutting, and drilling must be performed with care to prevent ignition. Draining and removal of all fuel and ventilation of vapors in vehicle and fuel system is recommended when performing such procedures. Proper eye and personal protection is required at all times during installation. DO NOT smoke, have lighted substances, or carry open flame of any type around when working near the vehicle during installation of this kit, including road tests and final inspections. DO NOT have personal electronic devices near the vehicle during installation, to prevent possibility of igniting fuel. WARNING! The Vehicle s fuel system may be under pressure! DO NOT loosen any fuel connections until relieving all fuel system pressure. Follow all instructions herein to relieve the fuel pressure, prior to disassembly of the fuel system. The Fuel Level in the Tank MUST BE below 3/4 Full to prevent spillage when the Fuel Module is removed. Follow all instructions herein to prevent spillage of fuel. Begin installation with vehicle level, to also ensure that the vehicle's fuel tank is below 3/4 Full. Remove at least 4 gallons of fuel if unsure of fuel level. Application: This Installation Kit is intended to be used for replacement of OEM fuel pump system that is originally installed on vehicle. This kit applies to Ford Mustang GT500 Vehicles, between and including the years of This kit is intended for these specific vehicles that have a dual in-tank fuel pump (GT500 dual in-tank pump system). If this Kit is not correct, please contact your Fuelab distributor immediately for replacement or selection of an appropriate Installation Kit or exchange of applicable components. Reference Section 2 Getting to Know Your Vehicle, of these instructions for additional information regarding the differences between the GT Single Pump Systems and the GT500 Dual Pump Systems. Modification of the ECU (Electronic Control Unit) programming is required for installation of this Fuel System. The OEM Fuel System for this vehicle is returnless, while this Fuelab Fuel System is a Return Based System (Return Line being integrated). The ECU must be programmed to change modes of operation regarding the fuel system type. Use of an aftermarket programming tool is required. After installation of this product, "Dyno-Tuning" is recommended for peak performance. After installation of this Fuel System with a Base Pressure Setting of 39 PSID (relative to the manifold pressure), the vehicle should operate adequately for cruise operation, enough for safe transport to a Dyno-Tuning facility. This is due to the unique operating characteristics of the Fuelab Electronic Fuel Pressure Regulator (having a "zero slope" characteristic). Reference Section 1 Getting to Know the Fuelab System, of these instructions for additional information regarding the performance of the various Fuelab Components. Product Contents: Verify the contents of this box, against the list of components (Sheet 2) and the diagrams (Sheets 3 through 5, for Figures 1 through Figure 3) to ensure that nothing is missing. When laying out the components, keep the parts close to each other as displayed in diagram (for convenience). Also note that o-rings (reference Items 10 and 18) may be pre-installed on two of the components (reference Items 8 and 35). Contact your Fuelab distributor immediately for replacement, if any items are missing. While this kit is designed for designated vehicles, vehicle manufacturers routinely change production components, even during the same production year. Please contact Fuelab if the particular vehicle has different descriptions or components that are incompatible as described within these instructions , No Rev Sheet 1 of 20

2 ITEM Description Qty 1 Dip Tube Assembly (Return Line) 1 2 Flange 1 3 Support Bracket 1 4 Stud, #8-32 x 3/4" Long 2 5 Lock Washer, #8 (same as Item 28, but used for different purpose) 2 6 Nut, # Jet Pump Assembly (Eductor) 1 8 Inlet Fitting Adapter 1 9 Cap Screw, #10-32 x 1/2" Long 2 10 O-Ring, for Inlet Fitting Adapter (Size -015) 1 11 Cap Screw, #6-32 x 1/2" Long 2 12 Plain Washer, # Lock Washer, # Nut, # Straining Filter, In-Tank 1 16 Bracket, for Jet Pump 1 17 O-Ring, for Power Module (Size -146) 2 18 O-Ring, for Outlet Fitting (Size -908) 1 19 Retaining Ring 1 20 Fuelab Model Power Module Component 1 21 Fuelab Model Electronic Fuel Pressure Regulator Component 1 22 Wiring Harness Component, for Electronic Regulator 1 23 Fitting, Barbed (1/8"-NPT) 1 24 Screw, Adjustment 1 25 Plain Washer, 3/8" 1 26 Jam Nut, 3/8" Cap Screw, #8-32 x 3/8" Long 3 28 Lock Washer, #8 (same as Item 5, but used for different purpose) 3 29 Bracket, Regulator Mustang Tower 1 30 Fragola BL, Fitting, -8AN Strait Fragola , PTFE Stainless Steel Braided Hose 33' 32 Fragola BL, Y-Block, -8AN 2 33 Fragola BL, Fitting, -8AN Fragola BL, Fitting, -8AN Fitting, -8AN Port 1 36 Model Fuel Filter Assembly Component 1 37 Wiring Harness, Mustang 1 38 Cable Tie, 6"L Loop Clamp, 1/2" 9 40 Spacer 2 41 Self Tapping Screw, # Saddle Clamp, Filter 2 43 Self Tapping Screw, # Ring Terminal 1/4" Post, for 12 Gauge Wire 2 45 Ring Terminal #8 Post, for 12 Gauge Wire 2 46 Shrink Tube, 1/4"OD , No Rev Sheet 2 of 20

3 Figure 1 Contents of Total Fuel System Package, Part 1 Reference Sheet 2 for Bill of Material Listing by Item Number for Component Descriptions , No Rev Sheet 3 of 20

4 12X X 33 2X Figure 1 Contents of Total Fuel System Package, Part 1 Reference Sheet 2 for Bill of Material Listing by Item Number for Component Descriptions , No Rev Sheet 3 of 20

5 37 10X 38 9X 39 2X 40 2X 42 9X 43 4X 41 2X 44 2X 45 6X 46 Figure 3 Contents of Total Fuel System Package, Part 3 Reference Sheet 2 for Bill of Material Listing by Item Number for Component Descriptions , No Rev Sheet 5 of 20

6 Section 1 Getting to Know the Fuelab Fuel System: Features and Performance Ratings of Included Sub-Components: Power Module (Fuel Pump) Model Electronic Regulator Model Fuel Filter Model Outlet Port Size -8AN Military Port Rated Flow Rate PSI, 13.5V (750 3 Bar) Maximum Pressure Operating Voltage Fitting Sizes Seat Size Operating Voltage Maximum Flow Capacity Pressure Adjustment Range Filter Element Length Filter Element Rating Filter Element Material 100 PSI (6.8 Bar) (Note: Limited by Regulator, see below) 8-18 Volts -8AN Male Fittings (one inlet, one return) Standard 8-18 Volts 6.3 GPM at 35 PSID (1440 LPH at 2.4 Bar) Pressure Range "E" PSID ( Bar) 5 inch 10 Micron Cellulose (Paper) Replacement Filter Element Fuelab Model (Gasoline and Diesel Only Compatible) Compatible Filter Elements Fuelab Model Micron Stainless Steel Fuelab Model Micron Microfiber Glass This Fuelab Total Fuel System Package includes a Fuelab Model Power Module (Fuel Pump) that uses Brushless DC Motor Technology. This enables a function of the pump that includes a speed control function. By having a speed control function, energy required to power the pump can be minimized as a function of engine demand. By reducing energy during low demand operation (such as street driving, or low engine power), heat build-up in the fuel system can be minimized and therefore greatly reduce the risk of fuel system failure due to cavitation. This Fuelab Total Fuel System Package also includes a Fuelab Model Fuel Filter Assembly, containing a 10 micron cellulose (5 inch long) Filter Element. The replacement Filter Element is Fuelab Model Number For use of E85, Methanol or other oxygenated fuels, Fuelab recommends replacement of the Element (inside filter housing) with Fuelab Model (40 Micron - Stainless Steel) or Fuelab Model (6 Micron Microfiber Glass). The Filter Assembly and Fuel Pump supplied with this kit do not contain a check valve assembly. Fuel Pressure will drop quickly to zero after engine shut-down. The filter assembly (outlet cap) can be changed to include a check valve assembly to help maintain fuel pressure after engine shut-off. Contact Fuelab for details. This Fuelab Total Fuel System Package also includes a Model Electronic Regulator. To enhance the speed control capability of the Fuelab Fuel Pump (Power Module), a return style Electronic Regulator is also included. This regulator allows the automatic control of the fuel pump by measuring the return line flow rate , No Rev Sheet 6 of 20

7 How does the Electronic Regulator Work? Just like standard EFI regulators, these regulators begin to relieve pressure (back to the fuel tank) once the set pressure is achieved. As more and more flow is sent through the regulator (pressure climbs a little higher with extra amount of flow), the regulator relieves the excess flow back to the fuel tank. Our Patented Electronic Regulator (per U.S. Patent 7,810,470) takes this action one step further by placing a restriction valve along the return line (a special valve is incorporated into the return line fitting of the regulator, DO NOT REPLACE this fitting with another component, as this will force the operation of the system to go into high speed pump operation only). The electronics monitors the built-up pressure and controls the Prodigy Fuel Pump accordingly. If the pressure that is being read is too high, then the Prodigy Pump is signaled to slow down. If the pressure is too low, then the Prodigy Pump is signaled to speed up. This action not only allows the pump to operate at a reduced amount speed with low engine output, but also allows the return line flow rate to be relatively constant. This has an effect of negating the regulator s inherent mechanical regulation slope (This value is the amount of fuel pressure change per amount of flow rate difference through the regulator). An additional output from the Electronic Regulator can be used to track the fuel system operating condition. This 0-5 Volt analog output allows the user to use a data acquisition system, Engine ECM, general data logger, or simply a volt meter, to track how hard the pump is signaled to operate. The voltage is typically at about 1.5 to 2.0 Volts (depending on Pump Model used and other factors such as baseline fuel pressure) while engine is operating at idle condition. Typical full capacity has an output of approximately 4.5 Volts. This regulator controls the fuel pump directly. Because of this, variation of pitch and sound quality radiating from the fuel pump is to be expected, that is normally absent from traditional EFI fuel systems. Some small amounts of oscillation during operation may be present at various operating conditions. Initial starting typically calls to the pump to start in a full speed condition, until fuel pressure is achieved, then speed is greatly reduced. This too is a normal operating condition. A Look Inside: , No Rev Sheet 7 of 20

8 Section 2 Getting to Know Your Vehicle Standard Mustang GTs can have a GT500 version of the fuel system "added on" as an option. This GT500 version of the fuel system is available through Ford Racing. The Ford Racing Kit includes a wiring harness, a Fuel Pump Module that includes two in-tank fuel pumps as well as extra Fuel Pump Driver Module (FPDM). Both systems are returnless, wherein the Fuel Pump Driver Module (FPDM) controls electrical power to the Fuel Pump Module in an effort to control fuel pressure. Returnless fuel systems of this type do not have a regulator or a valve that controls pressure. The system operates such that fuel rail pressure is monitored by the ECU. The ECU then communicates with the Fuel Pump Driver Module (FPDM) to "speed-up" or "slow-down" the fuel pump to maintain constant pressure (relative to the manifold pressure). Differences between the Standard Mustang GT and GT500 Fuel Systems: The GT500 Fuel System has dual In-Tank Fuel Pumps within the Fuel Pump Module. Standard Mustang Fuel Systems have a single In-Tank Fuel Pump within the Fuel Pump Module (residing in the fuel tank). The Fuel Pump Module is located in the fuel tank that is accessible under the rear interior seat within the vehicle. The GT500 Fuel System has two Fuel Pump Driver Modules (Left Side and Right Side of Vehicle). Standard Mustang fuel systems have a single Fuel Pump Driver Module (Left Side of Vehicle only). The Fuel Pump Driver Module(s) reside in the trunk area along the rear panel, behind the interior trim panel. The GT500 Fuel System has a 6-Pin Connector at the Fuel Pump Module. The Standard Mustang Fuel Pump uses a 4-Pin Connector. The two different connectors have different hole sizes for fitment into the Flange of this kit. Reference Figure 4, to view the differences between these two connectors to verify if this kit is correct for the vehicle. Contact Fuelab immediately for advice regarding any discrepancies. The GT500 Fuel System has a different Fuel Sender Assembly as well (attached to the Fuel Pump Module in the Fuel Tank). The orientation and location of the Fuel Sender is different between the two types of Fuel Systems. This variation requires that two different Support Brackets are available to fit the Fuelab Flange (Reference Item 2). Reference Figure 5, to view the differences between the two different types of Fuel Senders. If the installer is not sure which system is installed on the vehicle, reference Step 6 through Step 8 in these instructions involving the removal of the rear seat lower cushion to gain access to the outside portion of the Fuel Module. This step can be performed prior to installation of this Fuel System Package. With the top of the Fuel Module exposed, the electrical terminal can be observed. Without removing the connector, the number of wires that feed into the connector can be counted to verify the Fuel System version. Reference Figure 4, below, the two different versions of the Fuel Pump Module Connectors. Figure 4 OEM Fuel Pump Module Electrical Connectors, Standard GT and GT500 Versions , No Rev Sheet 8 of 20

9 Below in Figure 5, is shown the two different versions of the Fuel Sender (attached to the Fuel Pump Module, inside the tank). The two versions are shown to be able to verify between the two versions, as well as provide resistance specifications. Figure 5 OEM Fuel Pump Module Fuel Senders, Standard GT and GT500 Versions Modification of the ECU (Electronic Control Unit) programming is required for installation of this Fuel System. The OEM Fuel System for this vehicle is returnless, while this Fuelab Fuel System is a Return Based System (Return Line being integrated). The ECU must be programmed to change modes of operation regarding the fuel system type. Use of an aftermarket programming tool is required. Below is a schematic diagram of the general plumbing of the new Fuel System (reference Figure 6). Figure 6 Fuelab Total Fuel System Package Schematic Plumbing Diagram , No Rev Sheet 9 of 20

10 Section 3 Prepare Vehicle for Fuel System Replacement: Prior to replacement of the Fuel System, the following steps MUST be performed. Performance of the following steps maximizes the safety of the installer and assists in a successful installation. Step 1: The fuel system must have the fuel pressure relieved, prior to proceeding with Fuel Module Replacement. To relieve the fuel pressure, remove (unplug) the Fuel Pump Relay, found in the Bussed Electrical Center (Position 21). The Bussed Electrical Center is located under the front hood of the vehicle, along the front right side of inner fender area. If the Fuel Pump Module Connector was unplugged during examination, then re-plug in connector. Step 2: Start engine and allow it to idle until the engine stalls. After engine stalls, continue to crank engine over for several seconds. Turn ignition switch to the "OFF" position. Step 3: Remove the Battery Ground Terminal to disable the Vehicle's Electrical System. The location of the battery is typically under the hood, along the rear right side of the fender area (unless relocated into trunk of vehicle). Step 4: Fuel level in tank MUST be 3/4 full or LOWER or spillage will occur when the Fuel Module is removed. If the fuel level is greater than 3/4 full, then excess fuel MUST BE REMOVED! Siphon or pump excess fuel from filler pipe into an approved fuel container if required. If the fuel tank is full, at least four (4) gallons must be removed, as the fuel tank capacity of the vehicle is 16 gallons. Step 5: Open trunk of vehicle. Remove loose items (not a part of the vehicle) from the trunk, and set aside. Remove the center black plastic interior panel toward the rear of vehicle. Removal of this panel will expose the FPDM(s). Lift and peel back the left side of the Trunk Mat. Step 6: Remove the rear seat from vehicle (lower section only). Two Cushion Release Tabs are located along the front of the rear seat (one on each side of the vehicle). With the seat removed from the vehicle, the two soft covers covering the Fuel Tank Access Points are shown. The left side of the vehicle (behind driver seat on US Models) is the access point for the Fuel Pump Module, while the Right Side Access Point has a module containing only a Fuel Level Sender for the saddle tank side of Fuel Tank. Section 4 Replacement of the Fuel Pump Module: Step 7: With a flat tipped screwdriver, carefully lift off the cover (left side of vehicle) from the body (keep the wiring that runs through the center intact if present, such as with GT500 Versions). Gently remove the Power/Sensor Connector from the Fuel Module. Step 8: Looking at the end of the connector, count the number of pins, to verify that the proper Fuelab Power Module System is being installed (Reference Section 1, Figure 4). Standard Mustang GT Fuel Pump Module: 4 Pins Mustang GT500 Fuel Pump Module: 6 Pins Disconnect the Fuel Line from the Fuel Pump Module, by depressing locking tab on fitting side. Step 9: Use a brass punch and a hammer or a service tool, to remove the Fuel Module Tank Ring (rotate part counter-clockwise to release lock). Clean and ready the Tank Ring for reuse, if undamaged. Replace Tank Ring if heavily corroded or damaged. Step 10: Gently remove the Fuel Module from the fuel tank (slight initial rotation may be required to free the module from the tank flange). During removal, a Siphon Fuel Line is attached to the OEM Jet Pump. This Siphon Fuel Line connects between the left side module to the Jet Pump on the Fuel Pump Module. Since the Mustang fuel tank is considered to be a "Saddle Tank", fuel from one side of the tank must be continuously pumped to the "Fuel Pump Module" side of the tank. Disconnect this line by depressing tabs on the side of fitting end. Once the Siphon Line is removed, the OEM Fuel Pump Module is ready for full removal. Step 11: Remove, clean and ready for reuse, the O-ring sealing the Fuel Module to the Fuel Tank. If the O-ring is damaged or hardened, then replace the O-ring (Reference Ford Part Number 3S4Z-9276-AA). Clean debris from the opening at the fuel tank. Inspect O-ring area for corrosion or damage after cleaning. If the mating surface is damaged, then the Fuel Tank must be replaced to prevent fuel leakage. Step 12: With the Fuel Module on a workbench, perform the following component recovery tasks (needed items from original OEM Fuel Module): Tag or identify the wiring by color at the connector, that connects the Fuel Sender to the electrical connector (Reference Figure 4). Remove the screw retaining the Fuel Sender to the Fuel Pump Module (Reference Figure 5, for reference to the physical appearance of this sensor). Remove the Fuel Sender from the Fuel Pump Module. If possible, remove the electrical terminals attached to the Fuel Sender. The wires can be cut and re-spliced later in these instructions , No Rev Sheet 10 of 20

11 Inspect the Fuel Sender for damage and ready part for reuse later in these instructions. A Multi-meter can be used (gauge to measure resistance in ohms) to verify the proper operation (measured resistance between the two wires that lead to the Sender). Swing the arm from one extreme side to the other and compare the values as referenced in Figure 5. The value of resistance can vary a little from the specification by about 10 ohms, and still be considered normal operation. Remove, cut or cable tie the wires leading to the power connector(s) to the fuel pump(s). These wires can be cut and insulated. Do not ground or route the power from these wires, even though power does not get through these wires after removal and disconnection of the FPDM(s). With the wiring unhooked or cut, gently squeeze the retaining clips at the electrical connector, to remove the electrical connector from the top of the OEM Fuel Pump Module. Clean and inspect the Electrical Connector (as well as the O-ring portion of Connector), for use later in these instructions. Step 13: Install the Inlet Adapter Fitting (Item 8) into the Fuelab Power Module (Item 20) as shown in Figure 7. Be sure to REMOVE the Port Protector or cap, prior to adapter installation! Be sure that the O-ring (Item 10) is in place on the Inlet Adapter Fitting, and lubricated. NOTE: DO NOT PINCH MOTOR WIRES! Line up slot of Inlet Fitting Adapter to clear wiring. Use the Cap Screws (Items 9) to secure Inlet Fitting Adapter. Tighten Cap Screws between in lbs(snug, DO NOT over-tighten). Figure 7 Installing the Inlet Fitting Adapter Step 14: Lubricate and install O-rings (Items 17) onto the Fuelab Power Module (Item 20). Lubricate the bore of the Flange (Item 2), and slip the Power Module into the Flange as shown in Figure 8. Although the orientation of Power Module relative the Flange is per installer's discretion, Figure 8 (and subsequent figures) can be used for a general reference. The Flange can be set on the fuel tank, to give the installer an idea for a preferred outlet orientation, prior to Power Module Installation into the Flange. Step 15: Slip the Retaining Ring (Item 19) into the ring groove of the Flange (Item 2), after installation of the Power Module (Item 20). The Retaining Ring should easily slip into groove and "snap" into place. For reference, the Retaining Ring can also be easily removed with a simple small flat tipped screw driver and "Spiral-off" out of the ring groove in the Flange. Step 16: The outlet cap portion for the Fuelab Power Module has two (2) 1/8"NPT ports to allow for Jet Pump(s). The two ports are plugged. Choose one of the ports (approximate area shown in Figure 9) and remove plug. It is best to use the port that will allow the Jet Pump to face rearward (Reference Figure 9 regarding orientation). Apply thread tape (Teflon Tape) onto the threads of the Jet Pump (Item 7). When applying thread tape, always leave to the first or leading thread uncovered (to prevent the leading edge of the tape from contaminating the fuel system). Use a large standard screwdriver to tighten the fitting. When the Jet Pump (Item 7) is beginning to get snug, note the direction of the flow arrows on both the fitting and body portions of the Jet Pump and shown in Figure 9. These arrows need to point downward (toward tube), otherwise the Jet Pump will not operate , No Rev Sheet 11 of 20

12 Figure 8 Installing the Power Module into the Flange Figure 9 Installing the Jet Pump Step 17: Install the Jet Pump Support Bracket (Item 16), as shown in Figure 10. BE CAREFUL WHEN INSTALLING THIS BRACKET, TO ENSURE THE MOTOR WIRES DO NOT GET PINCHED. The bracket must "slide" behind the wires, prior to the installation of the mounting hardware. The "Hook" feature of the bracket fits around the tube portion of the Jet Pump (Item 7). The bracket simply prevents the Jet Pump from rotating and the "hook" does not need to be tight against the tube of the Jet Pump. Install hardware (Items 11, 12, 13 and 14) as shown in Figure 10. Toque fastener between in lbs (snug, DO NOT over-tighten) , No Rev Sheet 12 of 20

13 Figure 10 Installing the Jet Pump Support Bracket Step 18: Lubricate the connector bore portion of the Flange (Item 2). Slip the recovered Electrical Connector (from Step 12) into the bore of the Flange as shown in Figure 11. Note the orientation of the connector, as it can be installed in two different directions. When installed, the electrical connector will "snap" into position into the machined slots of the Flange (reference Figure 11). Figure 11 Installing the OEM Electrical Connector to the Flange , No Rev Sheet 13 of 20

14 Figure 12 Attaching the OEM Fuel Sender onto the Support Bracket Step 18: Attach the Float Sensor (recovered from Step 12) to the Support Bracket (Item 3) as shown in Figure 12. Install hardware (Items 11, 12, 13 and 14) as shown in Figure 12. Toque fastener between in lbs (snug, DO NOT over-tighten) (torque fastener snug; to approximately 25 in lbs). Step 19: Thread Studs (Items 4) into Flange (Item 2) as shown in Figure 13. Loosely install the rest of the hardware (Items 4 and 6) finger tight (to this point of the instructions). The Bracket (Item 3) may have to be removed from the studs for the final installation step of the Fuel Module. For now, keep the nut (items 6) threaded and finger tight, for removal later in these instructions (Reference Step 22). Re-attach wiring to connector. Figure 13 Installing the OEM Fuel Sender to the Support Bracket , No Rev Sheet 14 of 20

15 Step 20: Slip the Straining Filter (Item 15) onto the port portion of the Inlet Fitting Adapter as shown in Figure 14. Note the general orientation as shown infield of drawing (relative to the position / alignment of the Fuel Sender). Figure 14 Installing the Inlet Straining Filter Step 21: Place the recovered (or replaced) Fuel Module O-ring from Step 12, onto the groove at the Fuel Tank Opening. Step 21: It is recommended to loosen and remove the Fuel Sender Support Bracket (Item 3) from the assembly at this time, by removing the Nuts and Lock Washers (Items 5 and 6, reference Figure 15). Set the Nuts and Washers aside (ready for installation during the next step). Having the support bracket loose during final installation will ease installation, as it can be moved around independently of the Power Module. Insert the module into the Fuel Tank Opening. Once the Module is most of the way (as well as the Fuel Sender Assembly), the support bracket can be re-attached, by slipping the bracket over the studs and CAREFULLY reinstall the Nuts and Washers. Tighten Nuts between in lbs (snug, DO NOT over-tighten). At this time, connect the OEM Siphon Line to the Jet Pump. Reference the orientation of installation as noted in Figure 15. Figure 15 Installing the Power Module into the Fuel Tank , No Rev Sheet 15 of 20

16 Step 22: With the Fuelab Power Module in place, slip the recovered Tank Ring into position. Use a brass punch and a hammer or a service tool, to install the Ring (rotate part clockwise to engage lock). Step 23: Install the Dip Tube Assembly (Item 1) in Flange as shown in Figure 16. The Nut on the Dip Tube Assembly can be used (tighten or loosen relative to the assembly), to be able to adjust to the desired orientation. Tighten the nut portion of the Dip Tube Assembly to ft lbs of torque. The Outlet Fitting of the Power Module can be temporarily removed to assist in the installation of the Dip Tube Assembly. If the Outlet Fitting is removed and re-installed, be sure to tighten the three screws back in place using a "cross-torque" method of tightening. Figure 16 Installing the Dip Tube Assembly Section 5 Preparation and Mounting the Electronic Fuel Pressure Regulator Step 23: Attach the Regulator Mounting Bracket (Item 29) to the Electronic Fuel Pressure Regulator (Item 21) by using the fasteners as shown in Figure 17 (reference Items 27 and 28). Tighten Cap Screws (Item 27) between in lbs (snug, DO NOT over-tighten). Install the Adjustment Screw (Item 24) finger tight. Once the Adjustment Screw makes contact with the Spring Guide (at finger tight), turn an additional 2-1/4 turns further. This will give an approximate setting of 39 PSID. Place the Plain Washer (Item 25) over the Adjustment Screw, and thread the Jam Nut (Item 26). Tighten Jam Nut Finger-Tight until after pressure adjustment procedure later in these instructions. Figure 17 Installing the Electronic Regulator Hardware , No Rev Sheet 16 of 20

17 Step 24: Locate support bracket on the right side-front strut tower, toward the engine. This location can be used for different purposes, depending on the amount of modifications that vehicle has gone through. If this strut bracket is missing from the vehicle, then bend or modify the Regulator Bracket (Item 29), and mount against an appropriate section of the strut tower, that provides clearance for the regulator and mounting hardware (not included in kit, may be part of the vehicle). NOTE: Return line for Regulator MUST BE on the right side of the Regulator, reference Figure 17. Section 6 Replacement / Installation of Fuel Line Step 25: Trace the path for the OEM Fuel Line of the vehicle (note the path, as an optional path for the replacement Fuel Line (Item 31, to be used for both Supply and Return lines). The Installer may remove the OEM fuel line and OEM Filter per Installer's / Owner's discretion, as it will no longer be used. Reference Figure 6, for the general plumbing schematic for the fuel system. Different fittings may be required for the particular application due to induction differences and installer preferences. Cross Reference the proper Fragola Fittings, to ensure proper fitting replacement. ONLY Fragola Brand Fittings specified for their brand of 1/2" (-8AN) PTFE Hose are to be used with the supplied Fuel Line (Item 31). If a different brand or specification of fittings are used then plumbing failure and leakage will likely occur. Reference the Bill of Material (parts listing) on Sheet 2, for the cross reference of the Fragola Fittings and Hose used in this installation kit. Step 26: Ensure O-ring (Item 18) is lubricated and installed onto Port Fitting (Item 35). Thread Fitting into the Outlet Fitting of the Power Module. Torque Fitting between ft lbs (snug, DO NOT over-tighten). Step 27: The Fuel Line (Item 31) is coiled into a single length. Use a grinder / cut off wheel or other method for cutting the end of the braided line. Wrapping the location to be cut with masking or other stiff tape prior to cutting, will help minimize fraying of the steel braid. Some fraying at the end of the hose after cutting is inevitable, as long as the Socket portion of the fitting is capable of slipping over the braid, the cut is successful. Since different Installers / Owners may have different configurations regarding induction as well as different routing line routing preferences, each line must be "sized" in length, prior to cutting and installation. Reference Figure 18, showing and example assembly, orientation and order for assembly regarding the use of the supplied Fragola Fittings. The 90 Fittings (Items 33) and 45 Fitting (Item 34) is intended for use at the Fuel Rails (reference Figure 6). Figure 18 Installing Fragola Fittings onto PTFE Hose Step 29: Find a preferable location for the Fuel Filter (Item 36) underneath the vehicle along the planned route for the Supply Fuel Line. Some fabrication to the Vehicle may be required to find an appropriate location. Be sure that the Fuel Filter is well above the lowest point of the Vehicle, to minimize the possibly of damage as a result of "suspension bottoming out" and protection from general road debris. Use the supplied Saddle Clamps (Items 42) to mount the Filter. Use the supplied Self Tapping Screws (Items 41) or other suitable hardware) to secure the Saddle Clamps to the Vehicle. Step 30: Complete the Fuel System Plumbing, repeating the tasks as described in Step 27. The provided Clamps (Items 39) can be used at strategic locations, for securing the Fuel Line to the Vehicle. The supplied Self Tapping Screws (Items 43) can be used to secure the Clamps to the Vehicle , No Rev Sheet 17 of 20

18 Section 7 Installation of Wiring Harness / Electrical Step 31: Open Trunk, remove interior panel(s) along the rear of the vehicle to expose the Fuel Pump Driver Module(s). If the system was a GT500 Fuel System, remove both Fuel Modules from both sides of the vehicle (standard Mustang Fuel System has only one Fuel Pump Driver Module on Left Side of the vehicle). Loosen and remove the Fuel Pump Driver(s) mounting hardware (to be used later in these instructions). Step 32: Attach the Wiring Harness (Item 37) on the left side of the Vehicle on the rear panel that the left side Fuel Pump Driver Module was located. Use the recovered hardware (from Step 31) and Spacers (Items 40), to mount and secure the bracket portion of the Wiring Harness. Tighten hardware between in lbs (snug, DO NOT over-tighten) Step 33: At the bracket portion of the Wiring Harness (Item 37), an Orange or Red wire extends out of the wire covering, near the relay. Reference Figure19, to locate the proper wire to "Tap Into". Cut the indicated wire, leaving enough room for the wire at the Connector, for re-attachment later (in case the fuel system is to be converted back to OEM). The wire can be now spliced into the Wiring Harness. Be sure to splice the wire from the vehicle, not the connector!. Use solder and Shrink Wrap (Item 46) to make an acceptable wire splice. PIN: 1 SPLICE INTO THIS WIRE (PIN 2) PIN: 4 PIN: 5 NOTE: VERIFY VOLTAGE AT CONNECTOR, PIN 2. PIN: 2 Figure 19 Ford Fuel Pump Driver Module (FPDM) Connector Pin Identification Step 34: Route the rest of the harness along the floor of the trunk, leading to the front of vehicle (toward the installed Power Module). Step 35: Along the Harness (Item 37), the wiring comes to a "tee", branching off the wiring that leads to the Power Module. The cover may have to be modified (cut into the center) to lead the wiring from the "inside of the vehicle" to the Power Module. Remove the three Nuts and Lock Washers from the Electrical Terminals on the Power Module, and retain for re-installation. Slip the three Ring Terminals from the Wiring Harness (Item 37) onto the Electrical Terminals of the Power Module. NOTE: The Red Wire goes to the "+" Terminal with Red Insulator, the Black Wire goes to the "-" Terminal with Black Insulator and the Yellow Wire goes to the Center Terminal with Yellow Insulator. Replace the Nuts and Lock Washers back onto the Terminal Posts. Tighten Nuts between in lbs (snug, DO NOT over-tighten). Re-Install the Cover (seal the harness as needed) that sits over the Fuel Module. Step 36: Remove the Rocker Panel Interior Door Trim from the left side of the Vehicle. Lift the front of the vehicle (Safely and secure using Jack Stands and Wheel blocks with Parking Brake Engaged) to remove the Front Wheel of the Vehicle. NOTE: If the Battery has been relocated to the Trunk of the vehicle, the Power Wires (12 Gauge Wire) must be removed from the "Engine Compartment" end of the wiring and re-routed back to the read of the vehicle (the smaller 20 Gauge Wire and 12 Gauge Wire must be separated and soldered together at the "Tee" connection). Step 37: Along the Left Inner Fender Well, the wiring can pass through. If a hole is created to pass the harness through, be sure to use a grommet to protect the wiring and seal the passenger compartment. Route the wiring along the side of the Rocker Panel an through the Fender Well. Re-Install the Rocker Panel Interior Door Trim. PIN: 3 PIN: , No Rev Sheet 18 of 20

19 Step 38: Route Wiring into the Engine Compartment, toward the Battery or Right Side of Vehicle, along the Firewall. Use Cable Ties (Items 38) to secure the Harness to other wiring present in the vehicle. Step 39: Attach the Wiring Sub-Harness (Item 22) to the Connector of the Electronic Regulator (Item 21). Route the this Sub-Harness toward the Main Harness (Item 37), to get an idea of an appropriate location for splicing the Wiring Harnesses together (keep in mind the main power tap locations described per Step 40). Step 40: Select an appropriate Grounding Point and Power Tap area near the Battery of the Vehicle (may be the actual Terminals of the Battery). The Wiring Harness (Item 37) can be trimmed to remove excess wiring and wire covering. Step 41: After the determination of lengths and locations of the wiring (described per Steps 39 and 40), cut and strip the wiring at points that will allow easy splicing. Connect and splice the following wiring (using Solder and Shrink Wrap per Item 46): From the End of the Main Harness (Item 37): Red 12 Gauge (large) wire: Crimp and Solder to Terminal for "+" Battery Location (from Step 38). Select one of the available Ring Terminals (Items 44 or 45) or other appropriate connection as determined by the Installer. Black 12 Gauge (large) wire: Crimp and Solder to Terminal for "-" Battery Location (from Step 38). Select one of the available Ring Terminals (Items 44 or 45) or other appropriate connection as determined by the Installer. Red 20 Gauge (small) wire: Solder to Red wire from the Regulator Harness (Item 22). Black 20 Gauge (small) wire: Solder to Black wire from the Regulator Harness (Item 22). Yellow 20 Gauge (small) wire: Solder to White wire from the Regulator Harness (Item 22). From the Regulator Harness (Item 22): Green 20 Gauge (small) Wire: This wire must be insulated. The wire can be used for diagnostic purposes or routed to a Data Acquisition System if applicable (Reference Notes per Sheet 7). Step 41: Reconnect the Terminals to the Battery, and start vehicle. Engine may require cranking for several seconds to prime the fuel system. Once vehicle has started inspect the entire vehicle for possible fuel leaks. If fuel leaks are found, correct IMMEDIATELY! Step 42: Road test vehicle using only low power. Once determined that the Vehicle is operating (ECU may give warning due to missing FPDM) and not leaking fuel, Dyno-Tune engine for proper performance and software modification to change Fuel System Mode of operation for "Return-Style" Fuel System operation, not Returness operation as the ECU was originally programmed for. Consult Dyno-Tuning Shop (Tuner) for proper programming and final Engine Tuning procedures , No Rev Sheet 19 of 20

20 LIMITED WARRANTY FUELAB, a division of FCP, Inc., having its principal place of business at 1605 Eastport Plaza Drive, Suite 125, Collinsville, IL 62234, USA ("Manufacturer") warrants its FUELAB products (the "Products") as follows: 1. Limited Warranty. Manufacturer warrants that the Products sold hereunder will be free from defects in material and workmanship for a period of 2 Years from the date of purchase to the original purchaser. If the Products do not conform to this Limited Warranty during the warranty period (as herein above specified), Buyer shall notify Manufacturer in writing, or by phone, of the claimed defects and demonstrate to Manufacturer satisfaction that said defects are covered by this Limited Warranty. If the defects are properly reported to Manufacturer within the warranty period, and the defects are of such type and nature as to be covered by this warranty, Manufacturer shall, at its own expense, furnish replacement Products or, at Manufacturer's option, replacement parts for the defective Products. Removal of Products from vehicle (Vehicle means any automotive, bike or marine transportation powered by an internal combustion engine. This product is NOT intended or designed for use on aircraft, experimental or otherwise.), shipping to Manufacturer and installation of the replacement Products or replacement parts shall be at Buyer's expense. 2. Other Limits. THE FOREGOING IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. Manufacturer does not warrant against damages or defects arising out of improper or abnormal use or handling of the Products; against defects or damages arising from improper installation (where installation is by persons other than Manufacturer), against defects in products or components not manufactured by Manufacturer, or against damages resulting from such non-manufacturer made products or components. Manufacturer passes on to Buyer the warranty it received (if any) from the maker thereof of such non-manufacturer made products or components. This warranty also does not apply to Products upon which repairs have been effected or attempted by persons other than pursuant to written authorization by Manufacturer. 3. Exclusive Obligation. THIS WARRANTY IS EXCLUSIVE. The sole and exclusive obligation of Manufacturer shall be to repair or replace the defective Products in the manner and for the period provided above. Manufacturer shall not have any other obligation with respect to the Products or any part thereof, whether based on contract, tort, strict liability or otherwise. Under no circumstances, whether based on this Limited Warranty or otherwise, shall Manufacturer be liable for incidental, special, or consequential damages. 4. Other Statements. Manufacturer's employees, representatives' and/or resellers ORAL OR OTHER WRITTEN STATEMENTS DO NOT CONSTITUTE WARRANTIES, shall not be relied upon by Buyer, and are not a part of the contract for sale or this limited warranty. 5. Entire Obligation. This Limited Warranty states the entire obligation of Manufacturer with respect to the Products. If any part of this Limited Warranty is determined to be void or illegal, the remainder shall remain in full force and effect. 6. Warranty Service What Does This Warranty Not Cover? Any problem that is caused by abuse, misuse, or an act of God (such as a flood) is not covered. Also, consequential and incidental damages are not recoverable under this warranty. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you. How Do You Get Service? In order to be eligible for service under this warranty you MUST return the Warranty Registration card, or register on-line at within 30 days of purchasing the Product. If something goes wrong with your product contact FUELAB at , or send an to: info@fuelab.com for a Return Authorization Number (RMA). After receiving your RMA send it postage paid, fully insured, with a brief written description of the problem to: FUELAB Warranty Department, 1605 Eastport Plaza Drive, Suite 125, Collinsville, IL We will inspect your Product and contact you within 72 hours of receipt to give the results of our inspection and an estimate of the labor and/or parts charges required to fix the Product, if applicable. If covered under this limited warranty Manufacturer will repair Product and return it to you at no cost. If the Product is NOT covered under this warranty and if you authorize repairs, we will return the repaired Product to you COD, or prepaid via credit card, within 72 hours. There is no charge for inspection. If return product is found to be free of defects a $25.00 shipping and handling charge will be applied. We will return the repaired Product to you COD, or prepaid via credit card, within 72 hours , No Rev Sheet 20 of 20