Installation

CPR FUEL RAILS INSTALLATION INSTRUCTIONS

APPLICATIONS:

v 1996-2007 Ford Mustang GT/Cobra Intake

v Return or Return Less Style with Fuel Pressure Sensor fitting

v Included in CPR Package

1 Driver side rail (99-07 rail may have sensor fitting)

1 Passenger side rail

1 CPR stock fuel line to -8N fitting (supply)

1 CPR stock fuel line to -8N fitting (return, use on return style setup only)

1 Accessory Pack – CPR #1401500 (Return Style 96-98 or

1 Accessory Pack – CPR #1401600 (Return less style 99+)

WARNING

We recommend a certified auto technician for installation. You should have the following – a fire extinguisher, eye goggles and fuel resistant gloves Do not over tighten mounting –an fittings! Doing so will void your warranty as this will overstress the mounting tabs, therefore causing the weld to weaken and/or break. The OEM Fuel System is under pressure. This can cause serious injury if care is not taken to properly relieve it. You may open the gas cap to relieve the pressure. Some systems require additional steps using the Schrader valve. Another method is to let the vehicle sit overnight, as this allows ample time for the system to bleed down. Please refer to the service manual for more information.

Disconnect the negative battery cable to prevent accidental sparks with the fuel vapors that will occur with an open fuel system. Make sure the vehicle is well supported and the location is well ventilated with no open flames nearby like gas furnaces.

REMOVAL INSTRUCTIONS:

1. Remove the air inlet tube from the MAF sensor to the throttle body. Loosen the bolts holding the MAF housing on the fender, unplug the MAF sensor, IAT sensor and remove the idle air bypass tube. Remove the entire MAF housing, sensor and rubber tubing all in one piece.

2. Unplug the fuel pressure sensor (99+ vehicles). Unplug all injectors from the factory wiring harness. Carefully move the harnesses to the side, out of the way of the fuel rails. Make sure you can clearly see the fuel rails, mounting tabs and the 8mm bolts holding the rails on, and rear

crossover tubes. If the EGR bypass and/or shield are in the way (96 – 98 cobras), you may have to loosen or remove it. Make sure there is a clear path to remove the OEM rails by pulling straight up towards the hood.

3. Remove the stock fuel line(s) connected to the rails (99+up has only one feed line, no return). You will need the fuel spring clip adapters. These are available at any auto parts store. You may use A/C line service tools as they are of the same design. Remove the fuel pressure

sensor (if equipped) at this time.

4. Remove the 4 bolts holding the rails to the intake. Carefully and slowly, pull upwards on the fuel rail. This may require some additional force, be careful not to move farther than ½” at a time. The o-rings on the injectors, inserted in both the rail and intake are a very tight fit. Be

careful not to tear the o-rings on removal by rubbing against anything. One the rails have been removed, some injectors may be stuck in the rail and some may be stuck in the intake. Remove all injectors and keep in order.

INSTALLING THE NEW CPR RACING RAILS:

Do not tighten –an fittings if rails are installed on intake.:

5. Carefully inspect all of the injector’s o-rings for any tears or hardness. If any as suspect, replace immediately as a fuel leak may occur. Apply Vaseline to each o-ring (top and bottom) to coat the o-rings so they will not tear during reinstallation.

6. Test fit the new rails before installing any injectors. Do NOT torque down on any part of the rail. Check for proper clearance of the coil packs and water tubes. Some filing of the coil packs may be required. Some supercharged vehicles will have taller water tubes that came with the

supercharger kit and may interfere with the -8an fittings. Contact CPR if this happens at (248)398-2397.

7. Remove CPR rails from Step 6 above and install your OEM fuel pressure sensor that you removed in Step 3, onto your new CPR rails. Install injectors into new CPR rails (connector angles upwards). Position the rails with the logos facing forward of the motor and outward of the intake for proper orientation.

8. Install the -8N fillings included in the kit with the o-rings and any –AN fittings for the rest of your fuel system at this time. Be careful and use a thin piece of cloth on the rail. Then use a 1” open-ended wrench to hold the rail as you tighten the o-ring fittings.

DO NOT INSTALL THE –AN FITTINGS IF RAILS ARE INSTALLED!

9. Install the fuel rails by carefully lining up each injector for proper placement into the intake Once lined up, press down on front and rear of the rail to ensure proper injector alignment. After sealed, try to twist the injectors. They should be a little snug, but easily movable. If not, remove

the rail and injectors and reseal. Any binding could be an indication of a pinched o-ring. Remove and inspect and replace o-rings as needed.

10. Tighten down the Allen head mounting bolts for the rails. Continue to tighten down all other connectors and fittings. DO NOT INSTALL

THE –AN FITTINGS IF RAILS ARE INSTALLED! If you must, use the 1” wrench with a piece of cloth to hold the rail in place. The welded tabs for

the rails will not withstand the pressure of tightening the -8N fittings on the rails. Use extreme caution as this could void your warranty.

11. Use your -8N fittings and braided lines to complete the installation. Reconnect all wiring connectors and reinstall the air inlet tube and sensor connections. Before starting the vehicle, cycle the key on and off several times (at least 6 – 12 times) to build fuel pressure. Check for leaks under the rails and on top of the injectors. Check for leaks at each fitting. Once starting the car, check for leaks again.

When installing Cobra 4V or KB rails, refer to the following diagrams:

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