Aero-motive 14111 User manual

AEROMOTIVE
Part # 14111
98 ½- ’04 Ford 4.6L DOHC Fuel Rails
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.
The enclosed Aeromotive fuel rails utilize o-ring sealed AN-08 style ports; these ports are NOT
PIPE THREAD and utilize NO THREAD SEALANT. To use the enclosed fuel rails in your vehicle’s
fuel system you must install the necessary adapter fittings and o-rings, high pressure fuel lines
and regulator to adapt your system to the configuration and ports of these fuel rails. Please call
for a catalog of the complete line of quality Aeromotive products.
The enclosed Aeromotive fuel rails are intended to be installed on an unmodified OEM intake
manifold of the identified application. Aeromotive cannot guarantee the proper fitment on
aftermarket intake manifolds and the end user is responsible for verifying proper fitment and
assumes all liability.
When installing o-rings it is important to place a small amount of light oil on both the o-ring and
the mating surface to ease installation and prevent damaging the o-ring.
The following installation instructions are for a typical installation, for specific year and model
installation instructions please refer to your vehicles service manual.
Aeromotive system components are not legal for sale or use on emission controlled motor vehicles.

1. Once the engine has been allowed to cool, disconnect the negative battery cable and
relieve fuel system pressure, referring to the appropriate vehicle service manual for the
procedure on doing so.
2. Remove the air intake ducting.
3. Check for any dirt or debris around the fuel injectors. If any is evident, wash it off with
some solvent parts cleaner or wipe it off with a clean shop towel.
4. Disconnect the electrical connector at each injector, making note of the location of each.
5. Disconnect both the supply and return fuel lines from the OEM fuel rails. These lines are
attached by a special quick disconnect fitting which requires a special tool for removal.
Place clean shop towels around the open fuel lines to catch any gasoline that may drip out
and to prevent any dirt from entering the fuel lines.
Failure to satisfy all safety considerations will result in fire, explosion, injury and/or
loss of life to yourself and/or others.
6. Label and disconnect any electrical wiring, vacuum lines and throttle body components
that will interfere with the fuel rail removal and installation.
7. Remove the 4 mounting bolts that attach the fuel rail to the intake manifold.
8. Place clean shop towels around the injectors to catch any gasoline that may be spilled
during their removal. Remove the injectors from the manifold by gently pulling upward
on the fuel rail / injector assembly. Keep all injectors connected to the fuel rails. If an
injector does pull out of the fuel rail, it may spill a large amount of gasoline.
Failure to satisfy all safety considerations will result in fire, explosion, injury and/or
loss of life to yourself and/or others.
9. Carefully remove the fuel injectors from the OEM fuel rail.
10. Remove the old o-rings from the fuel injectors, inspect the injectors for any dirt or debris
and clean if needed. It is suggested that the old o-rings be replaced, contact your local
parts store or dealer to purchase the correct replacement o-rings.
11. Carefully install the new injector o-rings on the injectors.
When installing o-rings it is important to place a small amount of light oil on both
the o-ring and the mating surface to ease installation and prevent damaging the o-
ring.

12. Place a thin coat of light oil in the fuel rail injector bores and in the lower intake manifold injector
bores to help prevent cutting the o-rings during installation.
13. Carefully place each of the fuel injectors in the corresponding fuel injector bore of the
Aeromotive fuel rails.
14. Place each of the fuel rail / injector assemblies onto the lower intake manifold, ease the fuel
injectors into the injector bores in the lower intake being careful that the injector does not
dislodge itself from the fuel rail. When installing the right (Passenger) fuel rail, the center most
thread boss on the bottom side of the upper intake manifold may need slightly clearanced for
proper fit with the fuel rail, in some applications.
15. Place the provided aluminum spacer between the fuel rail mounting boss on the lower intake and
the fuel rail bracket, reinstall the rail mounting bolts and tighten.
16. With the Aeromotive fuel rail properly secured to the intake manifold, Move the fuel injector
vertically downward until it bottoms out on the intake manifold, In this downward position,
inspect the upper fuel injector o-ring (on the fuel rail side) and insure it is fully covered by the
fuel rail injector bore. If any of the o-ring is exposed, loosen the fuel rail bracket screws and
adjust the installation height until the o-ring is no longer exposed and retighten the bracket
screws. In the situation where the fuel injector has no vertical travel, either the fuel rail brackets
can be adjusted or the brackets shimmed until the fuel injector fits freely. Do not pressurize the
fuel rail until the proper fuel rail installation height is achieved.
17. Install the appropriate union fittings and o-rings in each end of the fuel rail, we recommend
Aeromotive p/n 15605 for AN-06 or Aeromotive 15607 for AN-08. The front of the fuel rail on
the right side (passenger) of the motor will be a close fit with the OEM coolant manifold, we
recommend using use a AN-08 male o-ring boss hose end, Aeromotive p/n 15665. As an
alternative using an Aeromotive fitting p/n 15605 AN-06 fitting in conjunction with an AN-06 90
degree hose end will clear.
18. Using an after-market fuel pressure regulator, We recommend Aeromotive p/n 13101, 13109 or
13129, (If you are converting the fuel system to a return style system) or a fuel pressure sensor
adapter similar to Aeromotive p/n 15112 (If you are maintaining the non-return style fuel system)
in conjunction with high pressure fuel lines and fittings, plumb the reminder of the fuel system.
Example of a return style fuel system plumbing

AEROMOTIVE, INC.
7805 Barton Street, Lenexa, KS 66214
913-647-7300 fax [phone]
www.aeromotiveinc.com
Ensure the any spilled gasoline and any gasoline soaked shop towels are cleaned up and
removed from the vicinity of the vehicle!
19. Reinstall any electrical wiring, vacuum lines, fuel lines, and throttle body components that
were removed during the original fuel rail removal.
20. Reconnect the battery and turn the ignition to the ON position WITHOUT starting the car.
After several seconds, check the fuel pressure. If there is no fuel pressure, turn the ignition
key to the OFF position, wait one minute, return the ignition to the ON position, and recheck
the fuel pressure. Repeat this ignition OFF and ON procedure until the fuel pressure gauge
registers fuel pressure.
21. With the fuel pressure gauge registering fuel system pressure, check for fuel leaks from
and around all the fuel system components and all fuel lines and connections! If any
fuel leaks are found, turn the ignition key to the OFF position, remove any spilled fuel
and repair the leak before proceeding!
22. Once the fuel pressure gauge registers fuel system pressure and there are no fuel leaks, start
the engine and adjust the regulator to the desired fuel pressure.
23. Once the desired fuel pressure is achieved, tighten the regulator adjustment jam nut and
attach the vacuum line.
24. Turn off the engine and allow it to cool.
25. Test drive the car to insure proper operation and re-check the fuel system for leaks. If any
leaks are found, immediately shutoff the engine and repair the leak(s)!

WARNING: This product can expose you to chemicals,
including chromium, which is known to the State of California
to cause cancer or birth defects or other reproductive harm.
For more information, visit: www.p65Warnings.ca.gov
Aeromotive, Inc. 7805 Barton Street, Lenexa, KS 66214 Phone: [phone] Fax: [phone]
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.
If a defect is suspected, the retail purchaser must contact Aeromotive directly to discuss the problem,
possible solutions and obtain a Return Goods Authorization (RGA), if deemed necessary by the
company. Please call 913-647-7300 and dial option 3 for the technical service dept. All returns must
be shipped freight pre-paid to the company and with valid RGA before they will be processed.
Aeromotive will examine any product returned with the proper authorization to determine if the failure
resulted from a defect or from abuse, improper installation, misapplication or alteration. Aeromotive
will then, at it’s sole discretion, return, repair or replace the product.
If any Aeromotive product is determined defective, buyer’s exclusive remedy is limited in value to the
sale price of the good. In no event shall Aeromotive be liable for incidental or consequential
damages.
Aeromotive expressly retains the right to make changes and improvements in any product it
manufactures and sells at any time. These changes and improvements may be made without notice
at any time and without any obligation to change the catalogs or printed materials.
Aeromotive expressly retains the right to discontinue at any time and without notice any Aeromotive
product that it manufactures or sells.
This warranty is limited and expressly limits any implied warranty to one year from the date of the
original retail purchase on all Aeromotive products.
No person, party or corporate entity other than Aeromotive shall have the right to: determine whether
or not this Limited Warranty is applicable to any Aeromotive product, authorize any action
whatsoever under the terms and conditions of this Limited Warranty, assume any obligation or
liability of any nature whatsoever on behalf of Aeromotive under the terms and conditions of this
Limited Warranty.
This Limited Warranty covers only the product itself and not the cost of installation or removal.
This Limited Warranty is in lieu of and expressly excludes any and all other warranties, expressed or
implied. This Limited Warranty gives you specific legal rights, and you may also have other rights
which vary from state to state.