Installation Instructions For Hellhorse® Twin Pump Fuel System
Notes and Disclaimers: Do this at your own risk. Hellhorse Performance is not responsible for any damage you do to your car or yourself. Install at your own risk. The process is of low to no risk but remember take your time and be careful when modifying your Mustang. If you at any point feel uncomfortable with the steps listed below we recommended you find a professional installer/shop to complete this process.
NOTE: MAKE SURE FUEL TANK IS BELOW ¼ FULL.
Unbox and inspect for the following components
- Red Power Wire
- Power with Fuse Block
- 50 AMP Fuse
- Assembled Control Board with Fuel Pump connector
- Fuel Pump Assembly
- 5 AN Fittings
- 15’ of Black E85 Fuel Hose
- Fuel Regulator with one side plugged and pressure gauge
- Unplug the Battery
- Remove rear lower seat
- Remove Door Sill trim pieces on passenger side
- Locate rubber grommet in firewall above interior fuse box
- Run power wire through grommet to battery location
- Run power wire along door sill and back seat
- Unplug electronics from factory fuel pump. (Remove Black Rubber Cover above fuel pump)
- Remove fuel lines from fuel pump assembly
- Remove locking ring that holds fuel pump assembly in place, using non-sparking tools
- Carefully remove fuel pump assembly, ensuring not to damage the float arm. (Note: There is a cross over tube attached to fuel pump assembly at the bottom that transfers fuel side to side of tank, this must be removed and reinstalled during removal and installation.)
- Take the Hellhorse® fuel pump assembly, set into the tank carefully, being careful to orientate the tab to the left, before dropping into tank completely, make sure cross over tube is connected.
- Gently press down the Fuel Pump Assembly, making sure O-Ring is in place, and seated properly, then reinstall locking ring, ensure it is fully locked to ensure no leaks
- Plug in electrical connector to the top of the fuel pump assembly
- Remove (2) two 10mm nuts on FPDM
- Take all ground wires with ring terminals on the Hellhorse® wiring harness and secure them under the FPDM with nuts
- Cut FPDM wire 1” back from gray connector – Purple/Green Wire
- Connect Purple/Green Wire to Signal Wire (Blue) on Hellhorse® wiring harness
- Cut Yellow/Purple and Green/Blue wire on factory fuel pump plug ½” back from gray plug
- Locate two butt connectors on the Hellhorse® harness, attach to the chassis side of the cut wires from step above
- Connect power wire ring terminal end to single post on control board, marked BATT. At this time snug all 3 nuts on the control board
- Elevate car on jack stands or lift, remove trim panels along drivers side under body (under the car)
- Run fuel line down through access hole/fuel tank side, pull the fuel line towards the front of the vehicle
- Attach 90 degree push lock fitting to fuel line, and attach LIGHTLY to the fuel pump assembly (return port)
- Run line to front of the engine bay, locate regulator and choose mounting location on the drivers side of the engine bay, mount regulator. Attach 90 degree push lock fitting to line after cutting fuel line to proper length allow access for fuel rail to regulator. And LIGHTLY tighten to the return (bottom) side of the Fore regulator.
- Assemble Fuel Rail Adapter with Straight fitting, attach to OEM Fuel rail, and OEM Fuel Line. Using the excess fuel line provided attach a line to the Fuel Rail Adapter (push lock fitting), and the other side to the 90 degree push lock fitting included, and LIGHTLY attach to Fore Regulator side port.
- Install Fuel Pressure Gauge on regulator
- Tighten ALL fittings and check ALL electrical connections
- Attach fuse block to supplied power wire and battery power
- At this point you need to test for fuel leaks and operation of the system. Power ON the car, and check for fuel leaks. You’ll know know if there is pressure via the gauge installed on the regulator (regulator should be set to 55-58psi(S550), 43-45psi (S197) WITHOUT vacuum reference. Any questions on this get with your tuner).
- If no leaks are found, start the vehicle and recheck for leaks.
- If no leaks are found, turn off the car.
- Reinstall all trim panels interior and exterior to OEM finish.
PERIODICALLY INSPECT ALL FITTINGS FOR TIGHTNESS, AND FUEL LINE INTEGRITY.