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a few seconds each time ignition switch is set to on. The fuel system will have to operate several seconds
(30+) to prime and drive air out of the fuel system. Inspect vehicle for any leaks. Turn off fuel system and
repair any leaks that may be present before continuing.
6. Follow other component installation instructions or other applicable service manuals to perform all applicable
inspections and determinations for an adequately operating fuel system.
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 Fuel Pump as well as internal straining filters) should be
checked and cleaned at least every 50,000 miles (more often for off-road operating conditions). Replace or clean
downstream filters (after Fuel Pump) every year or 15,000 miles (more often for off-road operating conditions).
Dirty fuel filters can block flow and adversely affect fuel system performance as well as can directly damage the
Fuel Pump and Fuel Pump Controller.
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.
Troubleshooting Notes:
Problem (Symptom)
Possible Causes
Possible Solutions
Not operating.
x
Faulty fuel pump relay.
x
Faulty, dirty or corroded
electrical connections or
improperly sized wire.
x
Faulty, dirty or corroded
electrical connections or
improperly sized wiring
between Controller and
Fuel Pump.
Check voltage to Fuel Surge Tank, 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.
x
Incorrect fuel system initial
priming procedure.
x
Improperly mounted Fuel
Pump or low fuel level.
x
Fuel Pump may be
operating in reverse
direction.
Repeat procedure for proper priming, check fuel
level as well as Controller voltage. Consult
Installation Step 5, herein. If verified that pump
operation may be reversed, consult "Fuel Pump
operating in reverse flow" on next line of these
Troubleshooting Notes.
Fuel Pump operating in
reverse flow.
x
Incorrect order for 3 phase
pump / motor wiring.
Switch two of the three pump / motor output
wires with each other. Consult Installation Step
4, herein and recheck fuel flow per Installation
Step 5, herein.
Please do not return this product to your retailer. If you experience any performance, reliability
or problems during installation or use of this product, please contact Fuelab immediately!
For more tips, advise or troubleshooting please visit our website at www.fuelab.com, e-mail
message to [email protected] or call our tech department at 618-344-3300 between 8am and
5pm Central Standard Time.