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How to Install a Thruster 500 Series Fuel Pump - Left Offset Inlet on your 1996-1997 Cobra Mustang

Installation Time

2 hours

American Muscle
Shop Parts in this Guide

ACCEL Thruster 500 Fuel Pumps

PART NO. 75169, 75340, 75341, 75342

NOTE: We recommend that the installation of this fuel pump be done at a qualified and licensed installation center by a licensed/certified 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.

WARNING:

You are about to start working on the vehicle’s fuel system that when opened, can be highly flammable. DO NOT ATTEMP THE WORK WHERE OPEN FLAMES AND OR POSSIBLE SPARKS CAN OCCUR OR ARE PRESENT. Extinguish all open flames; do not allow smoking and or any other type of flame ignition in the area where the vehicle is being worked on before proceeding with the installation. A working Fire Extinguisher must be present/nearby during the installation.

Always remember that the fuel system is under pressure even if engine has not been started during a lengthy period. Safely relieve all pressure before attempting to open the fuel system. Refer to the vehicle’s service manual for the proper procedure.

Vehicle Electrical System Check

• Before attempting to install this fuel pump, you must check the factory wiring for the proper wire gauge thickness that supplies power to the pump. The factory fuel pump wiring may not be sufficient to handle the current draw of this high performance fuel pump. We recommend the use of an aftermarket wiring kit. Please refer to page 4.

• If you use the existing electrical pump connector in your tank, you must ensure that the polarity is correct for your new pump. If necessary, re-pin the existing connector or use the included connector. If you use the new connector included in the kit. Make sure to solder the connections and use shrink tubing to protect the connection.

• The ACCEL THRUSTER 500 pump is the same physical size as many OEM in-tank pumps. This does not necessarily mean it is suitable for a particular application. Consult the ACCEL application guide first to determine if a THRUSTER Pump is recommended for your car, before proceeding with installation.

• The fuel pump basket or integral in-tank baffling may require modifications to allow sufficient inflow of fuel from the main tank. Failure of the basket or baffling to remain full of fuel during high engine load may significantly diminish the pump’s performance.

• Installing a new factory down-stream filter is HIGHLY recommended when installing this pump, and it should be monitored and serviced as needed to ensure fuel pump performance and service life.

• Your new ACCEL Fuel Pump is only one component part of your automobile’s complete fuel system. You must ensure the complete fuel system is up to the task of supplying fuel to your engine for the specific horse power needs to avoid severe engine damage.

Contact ACCEL if you have questions regarding your complete fuel system needs and requirements.

Note: Failure to follow the above recommendations may result in fuel leakage, bursting of the fuel lines, poor vehicle performance and/or decreased fuel pump life! Improper installation will void all warranties for this product!

CAUTION

Compatible Fuels – Race Fuel – Ethanol – E85- E95

• Due to the dielectric properties of Alcohol fuels like E85, fuel pump service life will be reduced and filter maintenance increased. Be certain alcohol compatible filters are installed and frequently maintained.

APPLICATION INFORMATION

ACCEL has made available specific application information informing what known vehicles have a fuel pump form-factor that is compatible with the ACCEL THRUSTER 500 pumps. Please find the application MML guide on our website at www. accel-ignition.com under the Support tab. Always check for product instruction/operation updates on our website before installing the product.

INSTRUCTIONS

For those familiar with purchasing aftermarket fuel pumps for installation as a replacement for the stock fuel pump, selecting the correct THRUSTER 500 pump is easy. Note: P/N’s 75340, 75341, 75342 and 75169 are configured as universal, in-tank replacement pumps, and feature the same form-factor (external dimensions) as 4 popular 255 LPH fuel pumps commonly sold under P/N’s GSS340, GSS341, GSS342 and 111169 respectively. There are many applications where these common, 255 LPH pumps are used effectively in the stock tank,

without major modifications, and those same applications may work as well with the new ACCEL THRUSTER 500 Pumps. To ease the determination of which ACCEL THRUSTER 500 pump may be used as an alternative, note that the last 2-digits of the ACCEL THRUSTER 500 Series part numbers correspond to the last two digits of the 4 common, 255 LPH pumps. For those that know which of the 255 LPH pumps will work in their tank, simply select the ACCEL THRUSTER 500 pump with the same last 2-digits.

For example, the 255 LPH GSS340 and the ACCEL 75340 will have similar form-factor and application. There are many applications where the ACCEL Pumps (and the same form factor 255 LPH pumps) will not work as a direct replacement. In these cases it is likely that some modifications have been made to the tank, the internal basket or baffling, and/or the fuel level sending unit to perform the installation. ACCEL neither sanctions or approves any modifications be made inside the tank to install one of these pumps, and any modifications that are made are done so at the sole discretion of the purchaser/ installer, with no guarantee of pump performance, service life, or assurance of compatibility made by ACCEL.

Note: Flow tests are done in a test lab. Length, inner diameter of fuel line/hose and amount of sharp bends in the line can diminish its flow rating. As a rule of thumb, consider utilizing 85% of the pump’s flow rating as a safety factor/cushion. Always remember; the fewer bends in the line, the fewer 90 deg fittings used and the shorter the line is from the pump to the engine will allow for more fuel to get to your injectors.

WARRANTY

ACCEL Performance, warrants its products only to the original purchaser at retail to be free from defects in material and workmanship for a period of 90 days from the date of original retail purchase, except that the following products have longer warranty periods:

• All distributors and starters have a limited one-year warranty.

• All ignition wires have a limited one-year warranty.

• THRUSTER 500 In-tank Pumps have a 2 year Limited Warranty.

WHO IS COVERED:

The warranty extends to original purchaser at retail only, WITH A PROOF OF PURCHASE. No exception.

WHAT IS COVERED: All parts which are defective in materials or

workmanship on original installation only, subject to the following:

WHAT IS NOT COVERED:

1. The use of Alcohol – Methanol - E85 – E95 and Synthetic type Race Gasoline with the THRUSTER 500 PUMP.

2. Products which have been subjected to abuse, accident, alteration, modification, improper installation, improper operational adjustments, tampering, negligence, misuse, or if repaired or serviced by anyone other than ACCEL Performance Group.

3. Actual or alleged labor. transportation or other incidental charges.

4. Actual or alleged consequential damages incurred by use of this product.

5. Specific for wire sets only: any wires which are burnt, abraded, cracked, torn, ripped, cut or otherwise damaged due to improper installation.

WHAT WE WILL DO:

ACCEL Performance Group, at its election, will either repair or replace all defective parts free of charge. WHAT YOU MUST DO FOR THE WARRANTY SERVICE: In the event that the original purchaser detects a defect in the material or workmanship, the product(s) in question must be returned by the original retail purchaser to the place of original purchase for warranty determination. In the event that the purchaser does not receive satisfaction from the place of original purchase or in the event there are any questions with regard to this limited warranty, please contact us by mail sent to the Technical Service Dept., ACCEL Performance Group, 10601 Memphis Ave., #12, Cleveland, OH 44144, e-mail your question to the Technical Service Dept. at www.mrgasket.com or call Technical Service at (216) 688-8300 ext. 5, Monday- Friday 8:30 a.m. to 5:00 p.m EST. Do not send alleged defective parts to ACCEL Performance Group without prior approval to do so. If such approval is obtained, the defective part and proof of purchase should be sent, postage prepaid, to ACCEL Performance Group at the above address for warranty consideration.

NO OTHER WARRANTY, EXPRESS OR IMPLIED, IS APPLICABLE TO THE PRODUCTS OR ACCEL Performance Group. THE DURATION OF ANY IMPLIED WARRANTIES, INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, IS LIMITED TO THE DURATION OF THE EXPRESS WARRANTY HEREIN. ACCEL Performance Group SHALL NOT BE LIABLE FOR THE LOSS OF USE OF THE PRODUCT, INCONVENIENCE, LOSS OR ANY OTHER DAMAGES, DIRECT OR CONSEQUENTIAL, ARISING OUT OF THE USE OF, OR INABILITY TO USE, THE PRODUCT OR FOR ANY BREACH OF ANY EXPRESS OR IMPLIED WARRANTY, INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE APPLICABLE TO THIS PRODUCT.

Some states do not allow the exclusion or limitation of incidental or consequential damages or limitations on how long an implied warranty lasts, so these limitations or exclusions may not apply to you. This warranty gives you specific legal rights and you may also have other rights which vary state to state. Materials, components, specifications, colors, model changes, availability and prices are subject to change without notice or obligation. Manufacturers’ brand names, trademarks and registered trademarks are used for reference only and are not to imply that any product is of their manufacture or any association herewith. ACCEL Performance Group makes no representation or warranty, express or implied, that its products comply with local, State or Federal emission levels, noise levels or safety standards. The purchaser assumes all responsibility for such use and compliance.

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