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Cartech Stage 3 Renegade Fuel System



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Renegade Fuel System Stage III Parts List & Instruction

 

P/N Description Qty   Notes:
21005 Fuel Pick Up Tube 1 Insert into tank
90099 Fuel Pump Assembly 1 Bolts to stock filter location
80002 Fuel Regulator 1 Mount in engine bay
22099 Fuel Filter 1 Bolts into stock location
20200 Fuel Rails (set) 1 Install in manifold
88667 Fuel Block 1 Between pick up tube and pump
An979-14d -10 to -6 Adapter 1 Side of regulator
An919-10-08 -10 to -8 Adapter 2 Both sides of pumps
An815-06d -6 to -6 Fitting 1 Bottom of regulator
An814-10d -10 Plug 1 Side of regulator
AN136-0106 -6 Straight Hose End 2 Bottom of regulator & at pick up return
An136-9006 -6 90 degree Hose End 2 Return on rails to side of regulator
An136-008 -8 Straight Hose End 2 Out of filter & feed rail to filter
An236-9008 -8 90 degree Hose End 4 Into filter and three ends of rails
An136-1010 -10 Straight Hose Ends 2 Out of pick up and into fuel block
An816-10d 3/8" to -10 Fitting 2 Pick up and fuel block
An816-08d 3/8" to -8 Fitting 3 Three ends on fuel rails
An816-06-06d 3/8" to -6 Fitting 1 Fuel Rail Return
An816-06d 1/4" npt to -6 1 Pick up return
1320 Hose Clamps (size 22) 4 Fuel line from fuel block to pumps
116-41 1/4" 90 degree Elbow 2 In fuel block
48-8-4 1/4" to " Hosebarb 2 In above elbows
200-06 -6 Steel Braided Hose 20' Return Line
200-08 -8 Steel Braided Hose 18' Feed line and crossover
200-10 -10 Steel Braided Hose 4' From pick up tube to fuel block
50102 Relay Kit 1 Relay, cb, t-tap
AD10 Adel Clamps Size 10 (1/2") 10 Secure Fuel Feed Line
AD8 Adel Clamps Size 8 (3/8") 10 Secure Fuel Return Line
Tek-10-1 1" Tek Sheet Metal Screws 20 Secure Adel Clamps

 
1) Install Pick up Tube. Fuel Pick Up Tube Instructions For Fuel Injected 5.0 Mustangs 86 to 95

          A. Drain gas tank. Jack rear of car up and place jack stands on the rear frame rails so that
     the rear axle will hang with no load. Drop the tank by removing the bolts at the end of the
     straps between the rear axle and the tank. Remove the small screw at filter neck. Use a
     jack or have someone help you when lowering the tank to avoid injury. Use caution when
     removing the tank, not to tear the rubber seal around the filter neck.

          B. Once the tank is down, disconnect the fuel level sending wires located in the middle of
     the tank. Then, remove the fuel lines at the tank. (CONTENTS MAY BE UNDER
     PRESSURE - TAKE PRECAUTIONS) Once fuel lines are disconnected from the tank,
     you can remove the retaining ring that holds the factory pump assembly in. Be careful with
     this ring and seal, you will reuse them later.

          C. Remove the Pump Assembly and the screen from the tank. Again USE CAUTION
     when removing, this is a vital part and needs to be re-used. We suggest a screw driver
     between the pump and screen to gently pry off.

          D. Prepare the CarTech pick up tube by installing the fittings you are using using Teflon
     tape on the threads. Hold pick up tube with a vise grip to install fittings.
     (DO NOT over tighten)

          E. With fittings installed, take the original pick up screen, clean, and snap onto the Cartech
     pick up tube. It will only go on the outlet tube, by simply snapping it to the end. The
     groove machined into the boss keeps the screen from coming off. Once it's on, it will not
     come off without destroying it. Rotate the screen so that it extends out with the natural
     curve of the pick up tube.

          F. Check the factory rubber seal ring for tears or cuts. If seal ring looks good, you can
     reuse it. If it has tears or shows signs of wear, replace it. After you've decided about the
     seal ring, put it back in it's original location. Install the pick up tube by sliding the screen
     into the slots on each side of the hole. Rotate the assembly towards the front of the car.
     The pick up tube will only fit in the tank the one way as described above.

          G. Re-install the retaining ring. Now you need to run your fuel lines to the tank for the
     pump and return lines. Once lines are run, attach wires for the fuel level sensor and mount
     the fuel tank. We suggest using silicone spray or WD-40 around the filter neck
     grommet for easier installation.

          H. Hook up your fuel lines to your pump and the rest of your car. It is critical to mount
     the pump at the midway point of the tank or lower. If you don't do this it can cause
     premature pump failure. We recommend using our pump mounting plate  for  exact
     placement.

2. Remove Stock Filter bracket and cut off the small tab that protrudes from near the stock filter.
Place CarTech filter into the stock brackets and tighten. Then put the stock bracket over top of
the pump plate provided and use factory bolts to secure both.

3. Run -10 Steel line from the Fuel Pick Up Tube to inlet side of the Y block using -10 Hose ends
at both ends. Then use two lengths of -8 line to go from the brass hose barbs to the inlets of both
pumps. These will be held on with hose clamps, not fittings. Run feed lines and return lines
along frame rail and secure with supplied adel clamps.

4. Install Fuel Rails
          A. Remove factory chrome feed, return lines, and fuel rails. (Contents may be under
     pressure, Take Caution) Remove injectors from original rails. Clean and cover to keep dirt
     and dust out.

          B. Take CarTech Fuel Rails and install desired fittings. Use loctite pst, liquid teflon or
     teflon tape. When using teflon tape do not run tape over the hole in the end, as pieces of
     teflon can get into an injector and clog it. (See diagrams 1 & 4 on following pages for
     proper fitting use. We recommend using diagram 1 with a CarTech fuel pressure
     regulator) Do NOT over tighten fittings into fuel rails, it can cause the rails to leak if done
     improperly.


                   Return Style Regulator                         Feed Side Regulator
 

          C. Take injectors and install them into the CarTech rails by using silicon spray or WD-40.
     Be careful not to pinch the injector o-rings and take your time. Once in, rotate clips to the
     outside of the rails.

          D. Set rails on the intake. The rail that is capped off goes to the front on the driver’s side.
     Use the spacers provided between the intake and the brackets if needed. (Stock distributor
     will need spacers on driver’s side only and MSD requires no spacers)

          E. Run -8 Braided Line in the back as a crossover. Then run the fuel inlet on passenger
     side and -6 return out of the driver’s side to the fuel regulator.

          F. When cutting braided line - mark it from the middle of the fitting, then wrap duct tape
     (or suitable tape) over the hose, center the mark on the hose to the center of the tape. Cut
     it with a saw, wheel, band saw or hack saw. De-burr and install into receiver part of the
     fitting (red part) and turn counter clock wise until hose is positioned just below the
     threads in the receiver fitting. Spray silicone or WD-40 into this hose and fitting. Then
     install the other part of the fitting. Be careful not to strip the threads. Tighten until both
     parts of the fitting are flush. Some adjustments may be required to ensure all fittings line
     up w/ no bind in the hose.

          G. When running your fuel line, do not run any lines through the drive shaft tunnel, not do
     you want to mount the fuel regulator to the firewall. Fuel lines must be on the outside of
     the frame rails and/or frame connectors. ANY deviation from these specific instructions
     could cause your vehicle to fail technical inspection or be disqualified from any N.H.R.A.
     owned or operated track, or any track following the N.H.R.A rules.  For further rules and
     regulations on fuel systems, please refer to page 140, section 1:5 of the N.H.R.A.
     Rule Book

          H. Tighten all of the fittings at all of the joints and prime the fuel system. DO NOT start
     your engine! Just prime to check for leaks at the injectors, rail fittings, regulator, and fuel
     inlet. To properly set and check pressures, it is recommended that you use a fuel pressure
     check gauge at the regulator or an -8 to -8 fitting supplied in the fuel systems. An under
     the hood gauge as well as a cowl or inside your car gauge will help in tuning your engine
     to it’s peak performance. Note: Do NOT run fuel inside the car; An isolator kit will be
     needed for cockpit mounted fuel pressure gauges.

          I. Once you have checked for leaks, start engine and check again. Periodically check
     fittings and hoses for leaks as well.

5. Mount the Regulator.
 A.   See diagram 4 for fuel rails.





6. Remove the inlet fitting to the rails and bleed the system to remove any debris from the lines.

7. Install the Relay Kit.
 A. See diagram. The diagram is your instructions.

8. Check the System for leaks and set fuel pressure.

Call our office  @ 210-333-1642 for further questions.

 

Telephone: 210.333.1642
FAX: 210.333.1749
Postal address: 18975 Marbach Ln, Suite#812, San Antonio, TX 78266
Sales E-mail: Mike Montgomery

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Last modified: 04/24/03