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of the fuel system. Reattach fuel rail line. Start fuel system and inspect for leaks. Inspect vehicle for any leaks.
Turn off fuel system and repair any leaks that may be present before continuing.
7. When adjusting pressure, be sure that fuel pump is operating to monitor pressure. Fuelab recommends to use
a “baseline” pressure reference when adjusting the pressure (adjusting the pressure with engine off or
Pressure
Reference
Line unhooked). The vehicle’s engine may not produce consistent vacuum during idle to have
repeatable readings.
8. After final adjustment of fuel pressure, tighten
Jam Nut
. Road test vehicle, and retest pressure upon return to
ensure accurate adjustment. After installation of this fuel pump, verify flow capacity to ensure safe levels of
flow, particularly with reduced levels of pump speed. Having insufficient flow capacity can result in an engine
lean-out condition that can cause severe engine damage. Collecting a given amount of fuel (as measured by
weight or volume) over a measured amount of time can be used to determine capacity. Collect fuel flow from
the return line to measure the amount of fuel capacity at a given operating pressure. A 20+ ampere capacity
battery charger may be used to simulate the charging system of the vehicle while engine is off. If using an
adjustable fuel pressure regulator, for boosted applications, simulate boost by raising the fuel pressure by the
amount of expected maximum boost pressure. Performing these tests will give greater accuracy for capacity
tests.
Fuel System Maintenance Notes:
Periodic inspection and general maintenance is required for longevity and reliability of the fuel system. This action
directly affects the fuel pump's performance and reliability. Included with that are periodic inspection and/or filter
element replacement. Straining Filters (upstream of pump) should be checked and cleaned at least every 15,000
miles (more often for off-road operating conditions). Replace or clean downstream filters (after pump) every year or
15,000 miles (more often for off-road operating conditions). Dirty fuel filters can block flow and adversely effect fuel
system performance as well as can directly damage the fuel pump.
Special alert for E85 or Methanol Users:
DO NOT
use cellulose (paper) based filter elements! Water can
contaminate the fuel and break down the element, creating debris that can damage injectors and fuel pump. E85,
Methanol and other oxygenated fuels can absorb water. Long term storage of this fuel within the fuel tank of
vehicle is not recommended and can contribute to rusting of the fuel pump's tool steel components. Draining the
fuel tank and replacement with small amount of Gasoline or Kerosene (along with operating the fuel system for a
small period of time) is recommended for long term storage of the vehicle.
Troubleshooting Notes:
Problem (Symptom)
Possible Causes
Possible Solutions
Not operating or slight
"clicking" sound when
turned on.
•
Faulty fuel pump relay.
•
Faulty, dirty or corroded
terminals or improperly
sized wire.
•
Debris from tank or
plumbing lodged inside
pump.
Check voltage to Fuel Pump, at power
terminals. If voltage is steady and consistent
(within 1/2 Volt of battery) then contact Fuelab
for assistance or repair. If voltage is
inconsistent as described, repair or replace
electrical components as required.
Not building up fuel
pressure.
•
Incorrect fuel system initial
priming procedure.
•
Loose inlet fuel fittings or
leaking plumbing on inlet
side (letting in air).
Repeat procedure for proper priming. If
condition continues, check all plumbing
upstream (on inlet side) of fuel pump.
Leakage of fuel at inlet or
outlet fuel ports.
•
Improper type of fitting
used.
If leakage is occurring between the end caps
and sleeve or controller base of pump, contact
Fuelab immediately for repair or replacement. If
leakage occurs at fitting, be sure that the proper
fitting style is used (AN o-ring seal type ONLY!).
Pipe Threaded style fittings are NOT to be
used. If proper style of fittings are being used,
be sure that o-ring is being used on fitting or
replace o-ring.
