Ford 5.0L EFI Firewall Forward Russell Plumbing Kit Installation Instructions
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.
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.
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.
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