Part # 5010
Universal 5.0L Fuel Rail Kit
w w w . B B K P E R F O R M A N C E . c o m
I N S T A L L A T I O N
I N S T R U C T I O N S
STEP 1
Disconnect negative battery terminal.
STEP 2
Remove intake hose between the mass air meter and throttle body.
STEP 3
Remove the distributor.
(Use a marker pen to mark the position of the rotor on the lower
cup of the distributor. Also note where the distributor base is at the engine block. Your distributor
should have a hash mark on it for ease of reference. This will help reassembly)
STEP 4
If your intake manifold has a decorative plate (5.0 H.O.) on top, you will need to remove the plate.
Use the T-20 Torx to remove the screws. Unclip the wiring harness locator from the manifold.
STEP 5
Disconnect the electrical, coolant, vacuum, and cable connections at the throttle body, EGR
valve, fuel pressure regulator, IAC valve, and the upper intake manifold.
(Some of the vacuum lines are
underneath and behind the upper manifold)
STEP 6
Using a ½” socket and extension remove the upper intake manifold bolts.
Slide the manifold towards the front of the car and disconnect the vacuum lines that attach to the rear of
the manifold and the PCV. Remove the upper manifold.
STEP 7
Unplug the wiring harness from the fuel injectors
(Be sure to only pull on the plastic plugs,
never pull by the wires.)
WARNING!
FUEL SYSTEM MAY BE UNDER PRESSURE. USE EXTREME CAUTION WHEN RELEASING PRES-
SURE. EXTINGUISH ALL OPEN FLAMES AND IGNITION SOURCES.
STEP 8
Remove the black plastic cap on the fuel feed line near the front end of the passenger side valve
cover (near oil filler cap). While holding a rag over the valve to avoid fuel spray,
carefully
release any fuel
system pressure by depressing the Schrader valve using a small screwdriver or pick.
STEP 9
Use the fuel line disconnect tools to separate the fuel feed and return lines from the injector rails.
STEP 10
Unbolt and remove the injector rails from the lower manifold
(The fuel rails will have excess
fuel in them, use caution when removing to avoid spillage)
STEP 11
Remove the fuel injectors from the lower manifold.
(Check each injector to make sure that
both of the O-rings are in place. The O-rings have a tendency to get stuck in the fuel rails)
STEP 12
Separate the fuel pressure regulator from the stock fuel rail.
(Skip this step if you are install-
ing an aftermarket regulator).
STEP 13
Inspect the injector tips and O-rings for cracks or damage. If you have any questionable items
we recommend replacing them
(available through auto parts stores).
STEP 14
Install the supplied mounting tabs onto the fuel rails using 8 of the 9 supplied
10-32 x 5/8” button head screws.
IMPORTANT- All appropriate safety equipment(i.e: gloves,tools) must be used during the installation of these product(s).
BBK Performance, Inc. accepts no responsibilty for injuries resultisng in the installation of any product(s).
MORE ON
THE BACK
!
CAUTION!
Working with Fuel Systems is hazardous. Extinguish any open flames and ignition
sources when working with gasoline and vapors. Always wear protective eyewear!
TOOLS REQUIRED
Hose Cutter
T-20 Torx
Ratchet
Allen Wrench set
Phillips head screwdriver
5/16” & 1/2” sockets Fuel Line Disconnect tool(spring lock type)
INCLUDED IN THIS KIT
Drivers side rail(SUB420), Passenger side rail(SUB421), Regulator mount,(SUB402), pre-assembled
hoses & hardware
INS-103
