Introduction: Unlock 60+ Horsepower with the Edelbrock E85 Fuel System

The Ford 5.0L Coyote engine is a powerhouse from the factory, but it leaves significant headroom on the table when it comes to fueling. Swapping to E85 ethanol fuel can unlock substantial gains—often 60 horsepower or more—thanks to the fuel's higher octane rating and cooling effect. The Edelbrock E85 Fuel System is purpose-built for Coyote engines, delivering the increased flow capacity needed to support these power levels without leaning out under boost or high RPM. This guide walks you through a complete installation, from removing the stock fuel system to configuring the new hardware for maximum performance and safety. Whether you are a first-time DIYer or an experienced builder, following these steps precisely ensures a reliable, leak-free system that delivers the promised gains.

Why Upgrade to E85 and the Edelbrock System?

E85 (85% ethanol, 15% gasoline) has an effective octane rating of around 105, allowing more aggressive ignition timing and higher boost levels. It also has a high latent heat of vaporization, cooling the intake charge and reducing knock. However, E85 requires approximately 30% more fuel volume than gasoline to achieve the same air-fuel ratio. The factory Coyote fuel system is not designed for this extra demand. The Edelbrock system includes a higher-flow fuel pump, larger injectors, and a return-style fuel pressure regulator to maintain consistent pressure under load. It is compatible with both naturally aspirated and forced-induction builds.

Key benefits of the Edelbrock E85 setup:

  • Flow capacity: Supports up to 800 flywheel horsepower (on E85) with the included pump and injectors.
  • Materials compatibility: All components are ethanol-resistant—stainless steel internals, Viton seals, and PTFE-lined hoses prevent corrosion and swelling.
  • Drop-in installation: Designed to fit the Coyote fuel tank and engine bay without major modification.
  • Tune-ready: Works seamlessly with aftermarket ECUs or custom calibration tools like HP Tuners, SCT, or Ecutek.

Safety note: E85 fuel is more corrosive than gasoline and can damage standard rubber fuel lines, seals, and fuel pumps. Always use ethanol-rated components. The Edelbrock kit is fully compliant, but verify any reused fittings or lines are rated for high ethanol content.

Tools and Materials

Before beginning, assemble all tools and parts. The Edelbrock E85 Fuel System comes as a comprehensive kit, but you will need a few additional items for installation.

Edelbrock E85 Kit Contents (Typical Part # 15468 or 15469)

  • Fuel pump module assembly (includes ethanol-rated pump, sender, and fuel level float)
  • Fuel injectors (80 lb/hr or 105 lb/hr depending on kit)
  • Fuel rails with ethanol-resistant O-rings
  • Return-style fuel pressure regulator (adjustable)
  • Fuel line kit: PTFE-lined stainless steel braided hoses with AN fittings
  • Mounting hardware, brackets, and wire harness adapters
  • Detailed instruction manual

Required Tools

  • Basic hand tools: socket set (¼” and ⅜” drive), combination wrenches (8mm–15mm), Torx bits (T25, T30, T40)
  • Fuel line disconnect tool (Ford-specific quick-connect style, ⅜” and 5/16”)
  • Torque wrench (ft-lb and in-lb)
  • Fuel pressure gauge (0–100 psi) for testing
  • Safety glasses and nitrile gloves
  • Shop towels, fire extinguisher (rated for fuel fires)
  • Jack and jack stands (if needed for fuel tank access – on many Mustangs the pump is in-tank and accessible through trunk/back seat)
  • Ethanol content tester (to verify E85 quality at the pump)
  • Wire stripper/crimper and heat shrink (if modifying the pump wiring)
  • Pan for fuel spillage

Preparation Steps

Proper preparation prevents fuel leaks, electrical shorts, and wasted time. Work in a well-ventilated area away from open flames.

  1. Disconnect the battery. Remove the negative terminal and secure it away from the post. This eliminates the risk of accidental sparking during fuel line or wiring work.
  2. Relieve fuel system pressure. Locate the fuel pump fuse in the engine bay fuse box (check your owner’s manual). Remove the fuse, then crank the engine for 5–10 seconds until it stalls. Crank again for a few seconds to confirm no pressure remains. Optionally, disconnect the inertia switch or fuel pump relay.
  3. Drain the fuel tank. If the tank is full, consider siphoning fuel into an approved container. A nearly empty tank reduces weight and spill risk when dropping the pump module.
  4. Clear the workspace. Ensure the area around the fuel tank access panel (under rear seat or trunk) is clean. For 2011–2023 Mustang GTs, the pump is accessed through a metal plate under the carpet in the trunk or behind the rear seat back. Remove any trim as needed.
  5. Lay out the Edelbrock kit. Verify you have all components. Compare the injectors and pump part numbers against the included build sheet. Some kits include different injector sizes depending on your horsepower target.

Important: Do not smoke or allow any ignition source near the work area. Even small fuel spills create flammable vapor. Keep a fire extinguisher within arm’s reach.

Removing the Stock Fuel System

Removal involves three main sub-systems: the fuel pump module (tank), the fuel lines, and the injectors/rail. Perform each step carefully to avoid damaging plastic components or O-rings.

Step 1: Remove the Stock Fuel Pump Module

  1. Remove the access cover (usually held by four 10mm bolts). Under it you will see a black plastic locking ring securing the pump module.
  2. Disconnect the electrical connector from the module. Press the locking tab and pull straight up.
  3. Using a fuel line disconnect tool, detach the main supply line from the pump assembly. Place a shop towel underneath to catch residual fuel.
  4. Using a large screwdriver or a fuel pump locking ring wrench, rotate the locking ring counterclockwise to free it. Lift the ring away.
  5. Carefully lift the pump module out of the tank. The float arm can snag on the tank opening; tilt the module slightly as you extract it. Set it aside—do not discard, as the new module may reuse the tank seal.
  6. Inspect the rubber gasket on the tank opening. Replace if dry-rotted or deformed. Some Edelbrock kits include a new gasket.

Step 2: Disconnect and Remove the Stock Fuel Lines

  1. Trace the supply line from the tank connection forward along the chassis. On Coyote vehicles, it runs along the driver side frame rail.
  2. Using quick-disconnect tools, disconnect the line at the fuel rail connection and at the chassis midpoint (if applicable). On 2015+ models, there is often a secondary connection near the firewall.
  3. Remove the line retaining clips and gently pull the line free from its guide mounts. You may need to loosen a few bolts holding the line brackets.
  4. Repeat for the return line (if your stock system has one—many returnless systems do not; the Edelbrock system converts to a return-style, so you will run a new return line).
  5. Set aside the stock lines. They are not compatible with E85 and should not be reused.

Step 3: Remove the Fuel Rail and Stock Injectors

  1. Remove the engine cover (three screws or pull off).
  2. Unplug each injector electrical connector by pressing the metal clip and pulling.
  3. Remove the two 8mm bolts holding the fuel rail at each end. On Coyote engines, the rail is mounted to the intake manifold.
  4. Gently pry the fuel rail upward with a flat-head screwdriver (place a rag under the tip to avoid scratching). The injectors will pop out of the intake manifold.
  5. Remove the retaining clips from each injector and slide the injectors out of the rail. Discard the old O-rings.

With all factory components removed, clean any debris from the intake manifold injector bores and the fuel tank opening.

Installing the Edelbrock Fuel System

Now you will install the Edelbrock components in reverse order, but with critical differences: larger lines, a return-style regulator, and upgraded pump wiring.

Step 1: Install the New Fuel Pump Module

  1. If the Edelbrock pump module does not come with the fuel level float pre-installed, attach it according to the included diagram. Ensure the float moves freely.
  2. Transfer the tank seal (gasket) from the old module onto the new one if needed. Apply a thin film of clean motor oil to the rubber seal for easier seating.
  3. Lower the new module into the tank, tilting it to fit the float arm through the opening. Press it down until the module’s top flange sits flush with the tank.
  4. Place the locking ring over the module and rotate it clockwise until it clicks and is tight. Do not use tools to overtighten—hand tight plus a slight nudge with a screwdriver is sufficient. Over-tightening can crack the plastic housing.
  5. Reconnect the electrical connector. The Edelbrock pump may have a different pigtail; if necessary, cut and splice the factory connector using the provided adapter or solder connections. Heat-shrink all splices.
  6. Attach the new supply line from the kit to the module output. Use the supplied AN fitting and tighten securely with a wrench—do not over-torque.

Step 2: Install the New Fuel Rails and Injectors

  1. Lubricate the O-rings on the new Edelbrock injectors with a tiny amount of clean engine oil or assembly lube.
  2. Install the injectors into the new fuel rail. They should snap into place with the retaining clips. Orient the electrical connectors consistently.
  3. Position the rail assembly over the intake manifold injector ports. Push down firmly until each injector seats fully into the manifold.
  4. Install the two mounting bolts at each end of the rail. Torque them to Edelbrock specs (typically 89 in-lb / 10 Nm). Over-tightening can warp the rail or crack the manifold.
  5. Connect the injector electrical connectors until they click.

Step 3: Route New Fuel Lines

  1. Attach the stainless steel supply hose from the kit to the fuel rail inlet. Use a wrench to tighten the AN fitting.
  2. Route the supply line along the original chassis path. Use the included clamps or zip ties to secure it away from hot exhaust components and moving suspension parts.
  3. Route the return line from the fuel pressure regulator (mounted on the rail or firewall) back to the fuel tank. The Edelbrock kit typically includes a bulkhead fitting for the tank return port. You may need to drill a hole in the access plate for the return line—check the instructions for your specific vehicle. On some Mustangs, a pre-existing return port on the tank module can be used.
  4. Connect the return line to the regulator outlet and to the tank. Tighten all connections.

Step 4: Mount the Fuel Pressure Regulator

  1. The adjustable regulator usually mounts on the driver side fuel rail. Install it with two provided bolts.
  2. Connect the vacuum reference line from the regulator to a manifold vacuum source (the intake manifold has a dedicated port).
  3. Do not tighten the adjusting screw yet. Set it initially to the base pressure recommended by Edelbrock (typically 43.5 psi at idle with vacuum disconnected).

Configuring the Fuel System

Once the hardware is installed, you need to prime and check the system before starting the engine.

Check for Leaks

  1. Reconnect the battery.
  2. Turn the ignition to the ON position (do not start) – the fuel pump will prime for 2–3 seconds. Listen for pump operation and any unusual noises.
  3. Inspect all connections with a flashlight. Look for drips or seepage at the pump, rail, and regulator.
  4. If no leaks are visible, proceed to set pressure.

Set Fuel Pressure

  1. Connect a fuel pressure gauge to the Schrader valve on the rail (if equipped) or tee into the line.
  2. With the pump running (ignition on), turn the adjustment screw on the regulator to achieve the target pressure. Clockwise increases pressure, counterclockwise decreases. Typical Edelbrock spec is 43.5 psi with the vacuum line disconnected and plugged. Reconnect vacuum and the pressure should drop 8–12 psi at idle.
  3. Lock the adjustment nut to prevent drift.

Verify Injector Operation

Use a noid light (injector test light) or an oscilloscope to confirm all eight injectors are firing when the engine is cranked. If one injector is not receiving power, check your wiring and the ECU connector.

Pro tip: If you are installing the system alongside a forced induction upgrade, consider upgrading the fuel pump wiring with a direct battery feed and relay kit. The Edelbrock pump draws higher current than stock, and factory wiring may introduce voltage drop. A dedicated wiring harness improves pump performance and reliability.

Tuning for E85

The Edelbrock fuel system alone will not produce 60+ horsepower gains. You must retune the engine management system to take advantage of E85’s properties. Running E85 without a tune can cause a lean condition and engine damage.

Acquire a custom calibration from a reputable Coyote tuner such as Lund Racing, Palm Beach Dyno, or VMP Performance. They will provide a file based on your modifications, injector size, and desired power level. If you are using HP Tuners or SCT software, you can self-tune with proper wideband O2 sensor feedback and data logging.

Key tuning adjustments for E85:

  • Air-fuel ratio: Lambda of 0.78–0.83 for naturally aspirated, 0.75–0.78 for forced induction (richer than gasoline).
  • Injector flow rate and offset: Update the injector data table with the EDELBROCK 80 lb/hr values (available from Edelbrock).
  • Spark timing: Increase timing by 2–4 degrees over the gasoline map, but monitor knock via live data.
  • Cold start enrichment: E85 is harder to ignite when cold. Add extra fuel in the cranking and warm-up tables.

After the tune is loaded, perform a data log of the first few pulls to verify fuel pressure holds steady and fuel trims are within ±5%.

Final Steps

  1. Reinstall all interior panels, trunk carpet, and engine cover.
  2. Fill the fuel tank with at least 5 gallons of E85.
  3. Start the engine. It may crank longer than normal due to the new fuel system volume. Pump the gas pedal once if needed to prime.
  4. Let the engine idle until it reaches operating temperature. Monitor for leaks, fuel odor, and any warning lights.
  5. Check the fuel pressure gauge while the engine idles. It should hold steady with small changes when the vacuum is applied.
  6. Take a short test drive at moderate throttle. Then gradually increase load to full throttle in a safe area. Look for hesitation, stumbling, or surging—these may indicate a fuel delivery issue or incorrect tune.
  7. Return and re-torque all fuel line fittings after the first heat cycle. The AN connections can loosen slightly as the system expands.

Conclusion

Installing the Edelbrock E85 Fuel System on a 5.0L Coyote is a direct path to 60+ horsepower gains, provided you pair it with a proper ethanol tune. The step-by-step process outlined here covers everything from stock removal to final test drive. Pay special attention to ethanol-rated materials, leak-free connections, and accurate fuel pressure adjustment. With the Edelbrock system delivering full flow, your Coyote will be ready to take advantage of E85’s high octane and cooling benefits.

For further details on your specific vehicle year, refer to the official Edelbrock E85 Fuel System product page. For additional tuning resources, visit the guide at American Ethanol Coalition. Coyote owners have also documented many installation tips on SVTPerformance forums.