Mustang V8-4.6L DOHC (1996)
Fuel Supply Line: Service and Repair
Removal and Installation
CAUTION: Ford-approved nylon tubing is made from material which has been tested and proven to be acceptable for use with commercially available
fuels. It is also resistant to most environmental conditions. Avoid using alternate tubing materials, as this could pose a hazard in service.
CAUTION: Nylon fuel tube must not be serviced using hose and hose clamps. Should the plastic tubes, push connect fittings or steel tube ends become
damaged and leak, approved service parts must be used to service the fuel tubes.
CAUTION: The plastic fuel tubes can be damaged by torches, welding sparks, grinding and other operations which involve heat and high temperatures.
If any service operation will be used which involves heat and high temperatures, locate all fuel system components, especially the plastic fuel tubes to
make sure that they will not be damaged. It is recommended that the plastic fuel tubes be removed from the vehicle if a torch or high heat producing
equipment is to be used for service in the following areas:
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Exhaust or suspension components in proximity to fuel tubes.
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Floorpan under vehicle and inside the passenger compartment (RH side).
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Rocker panel (RH side).
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Under body frames, rails and cross-members (RH side).
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Dash panel, under vehicle or inside the passenger compartment (lower RH side).
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Front or rear wheel house/fender apron (RH side).
REMOVAL
1. Perform fuel system pressure release procedure.
2. Drain fuel from tank.
3. Disconnect the push connect fittings from tubes at the fuel tank.
4. Lower the fuel tank, (if necessary, disconnect the push fittings from the fuel level sensor.
5. Remove the RH front fender liner from inside the front wheel housing if required to expose the fuel tube routing.
6. Disconnect the spring lock couplings from the engine tubes at the front of the vehicle.
7. Cut the push pins off between each plastic wrap-around clip and the body. Remove the screws from around any wrap around clips. Drill the pop
rivets out of any clips. All clips can be reused.
INSTALLATION
1. Secure the fuel tube assembly to the underbody near the center of the vehicle using a clip/retainer and pop-rivet.
2. Moving rearward, install all additional clips as shown on the system illustration for the correct location for this first clip.
3. Route the tube assembly forward to the front structure and into the RH front fender wheel housing.
NOTE: All clips must be located between the paired upsets in the tube assembly.
4. Install the special metal clip and secure it with a screw to retain the tube assembly in the depression under the front structure rearward of the wheel
housing.
5. On pressurized fuel systems, connect the plastic tube push connect fittings to the metal tubes or engine tubes at the front of the vehicle and to the
fuel tank, fuel pump and filter at the rear of the vehicle.
6. Return the drained fuel to the fuel tank.
7. Check the fuel tubes and push connect fittings for proper function. The push connect fittings must be installed so that the second bead on the tube
is inside the end of the fitting. Pull back on the fitting to make sure that it is completely installed.
8. Install the fender liner in the RH front wheel housing.
9. Install fuel pressure gauge on the fuel pressure relief valve. Turn the ignition switch from OFF to ON position for three seconds. Turn ignition
switch for three seconds repeatedly (5-10 times) until pressure gauge shows at least 241 kPa (35 psi). Check for leaks at fittings.