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AEROMOTIVE

Part # 17157

05’- Present Mustang Fuel System Chassis Kit

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 cell (18667)

1 ea fuel filter bracket (12305)

1 ea fuel filter (12321)

30 ft AN-08 black nylon braided line

3 ea p/n 15610 AN-08 to cutoff AN-10 union

2 ea p/n 15645 AN-08 tank fitting

4 ea p/n 15685 AN-08 bulkhead fitting

12 ea cushioned hose clamps

5 ea AN-08 straight hose end

1 ea AN-08 45-degree hose end

8 ea AN-08 90-degree hose end

12 ea self-drilling screw

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 drive shaft and exhaust system

may be necessary for fuel tank removal.

1-4. Once the OEM fuel tank has been removed, tie up all electrical connections and hoses that were disconnected.

1-5. Find a suitable place in the trunk to mount the fuel cell. For mounting use Aeromotive bracket P/N 18701, or call

Aeromotive. Here is a typical install of a fuel cell in a SN197, Figure 1-1.

Summary of content (9 pages)

PAGE 1
AEROMOTIVE Part # 17157 05’- Present Mustang Fuel System Chassis Kit 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.
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Figure 1-1 1-6. Find a suitable place for the two tank vent pass through fittings (15645), typical locations is trunk floor. Drill two holes making sure you place them in a location where you can get access to the back side for the lock nuts. The system comes with two tanks vents and both must be used for the system to function properly. 1-7. Assembly two identical hoses, 90 degree hose end on one side and a straight on the other. These will be used for the tank vent hoses, Figure 1-2. Figure 1-2 1-8.
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Figure 1-3 1-9. Install one of the supplied 15610 fittings into the outlet of fuel pump (Make sure the fitting has the AN-10 o-ring installed on it). 1-10. Assembly two hoses, both with 90-degree hose end on all ends. One will be used for the pump outlet and the other will be used for the return, figure 1-4. Figure 1-4 1-11. After connecting the return and pump outlet lines to the bulk heads, move to the under side of the vehicle. 1-12.
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Figure 1-5 1-13. Once the filter has been mounted, assemble a hose with a 90-degree fitting on one end and a straight on the other. This line will finish the connection from the feed bulk head to the filter, figure 1-6. NOTE: Make sure you connect to the pump outlet and not the return. Figure 1-6 1-14. In the engine bay find a suitable place for the two AN-08 bulk heads. Typical place for these are behind the passenger side strut tower, figure 1-7.
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Figure 1-7 1-15. Once you have both bulk heads installed, assemble a hose with a 45-degree fitting on one end and a straight on the other. This line will connect to the outlet of the fuel filter (45-degree hose end) and one of the bulk heads you just installed. 1-16. Finish up the last line by assembling a hose with a straight hose end on one side and a 90-degree on the other. This hose will make the connection from the return bulk head in the engine bay to the return bulk head in the trunk. 1-17.
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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.
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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 operation pressure prior to use.
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Section 3 – Final Checks and System Start-up 3-1. Ensure that any spilled gasoline and any gasoline soaked shop towels are cleaned up and removed from the vicinity of the vehicle! 3-2. Carefully lower the car onto the ground. 3-3. Fill the fuel tank with gasoline and check for any leaks in the system, if any leaks are found repair immediately.
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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.