3i. Install the Fuel Pump Assembly into the Fuel Tank and securing it with acquired fasteners (not supplied).
4. Install other fuel fittings (not supplied). The threads used on these fuel ports are not tapered or pipe threads.
Do not use Teflon
thread tape or thread sealant on these threads, as this can cause leakage or introduce
debris into the fuel system. Fittings to be used with this style of port require use of the enclosed -908 o-rings
for proper sealing. Use light oil to lubricate the o-rings just prior to installation. Install the O-rings onto the fuel
fitting first. Position the o-ring in the thread relief of the fitting. Thread fitting into fuel pump and tighten
between 5 and 15 ft
ꞏ
lbs of torque.
ALL
fuel line that is internal to tank
MUST
be fuel compatible both inside
and outside of the line. PTFE based fuel line is recommended for a long service life.
5. Upon installation of fuel tank or cell and installation of all other fuel system components, inspect fuel system for
any contact of fuel lines or wires with other components that can cause chafing or rubbing. Secure all
components and fuel lines. Ensure that moving components of vehicle are clear.
6. Connect the vehicle’s battery. Perform initial priming: The fuel pump may require priming during initial
operation and for moment after depletion of fuel from fuel tank or cell. This action can be accomplished by
removing fuel line from fuel rail (downstream of fuel pump and filters), allowing the fuel line to empty fluid into
fuel safe container. Operate fuel pump until fuel exits fuel line. Attach fuel line back to the fuel rail after priming
fuel pump. After tightening connection, verify leak-free operation while checking fuel rail pressure. If fuel
pressure is not high enough, repeat priming procedure to ensure that fuel pump is receiving fuel from tank.
Turn on fuel pump (typically by bypassing fuel pump relay) without engine operating. ECU or engine
management computer may be controlling the relay. The ECU may only operate pump for a few seconds each
time ignition switch is set to on. The pump will have to operate several seconds (30+) to prime and drive air out
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 using
a “baseline” pressure reference when adjusting the pressure (adjusting the pressure with engine off or pressure
reference line or vacuum 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.
110021251-1, Rev B Sheet 6 of 8
