Product Instructions
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1. Check the diagram and list of components Adjustment Screw right to ensure that no components are Regulator missing from box Contact your Fuelab 3X 906 O ring Plug distributor immediately for replacement pi Fitting 51502 Features and Performance Ratings 0 Inlet Port Sizes 6AN Military Port Seat Size Standard O Regulation Slope 3 PSI GPM Maximum Flow 2 5 GPM at 25 PSID Oo Q Capacity 570 LPH at 1 75 Bar Pressure Pressure Range E Adjustment Range 25 90 PSID sd eed Flat washer 1 75 6 2 Bar 3X Bracket Lock Washers 3X Bracket Screws WARNING Exceeding maximum flow capacity may result in an over pressure operating condition Before Installation Plan Entire Fuel System These instructions are limited to general topics of regulator component installation and may not include specific information pertaining to your application These instructions are written assuming the use of an electric fuel pump capable of at least 100 PSIG outlet pressure and limited to the specified Maximum Flow Capacity above This regulator has an internal spring that can be changed for other pressure ranges including T range for 10 25 PSID if required by the specific application Lower carbureted pressure ranges are recommended for a different model of regulator only Visit our company website for specific details pertaining to example fuel systems and other solution ideas Additional information including adv2. Model Number 51502 _ FUELAB Fuel Pressure Regulator Operating and Installation Instructions CAUTION This product is to be installed only by persons knowledgeable in the repair and modification of vehicle fuel systems and general vehicle systems modification Only a qualified technician or mechanic who is aware of applicable safety procedures should perform the installation of this product GASOLINE AND OTHER FUELS ARE FLAMMABLE AND CAN BE EXPLOSIVE Perform the installation in a well ventilated location only to minimize the build up of fuel vapors NO open flames smoking or other sources of ignition are to be present during installation to prevent fire or explosion that can cause serious injury or death Grinding cutting and drilling must be performed with care to prevent ignition Draining and removal of all fuel and ventilation of vapors in vehicle and fuel system is recommended when performing such procedures Proper eye and personal protection is required at all times during installation The Vehicle s fuel system may be under pressure Do not loosen any fuel connections until relieving all fuel system pressure Consult an applicable service manual for instructions to relieve fuel system pressure safely This product is intended for racing off road or marine use only This fuel system component is capable of altering engine tuning and therefore not legal for sale or use on emission controlled motor vehicles Product Contents
3. anced troubleshooting any special alerts and FAG s pertaining to this and other products is also available General Regulator Performance Notes The notation PSIG means pressure in Pounds per Square Inch PSI relative to the prevailing atmospheric condition or outside air This is referred to as Gauge Pressure The notation PSID means pressure in PSI relative to another pressure source or called the Differential Pressure The intake manifold pressure when plumbed to the regulator changes the fuel pressure in a 1 1 ratio When the engine idles for example 12 Inches of Mercury or 6 PSIG of vacuum fuel rail pressure will lower 6 PSI when compared to the setting with the engine off For boosted applications including turbo or superchargers fuel rail pressure increases at a 1 1 ratio An engine at 10 PSIG of boost as measured in the intake manifold will increase the fuel pressure by 10 PSIG The actual readings of pressure in a real world application would show a lower pressure as the engine is using fuel that would normally be returning back through the return line when the engine is off The amount of pressure difference to expect is a function of how much flow the engine is using reference Regulation Slope above 105020121 1 RevA Sheet 1of4 Plumbing Planning Notes Minimize plumbing restrictions between fuel rail s and regulator for peak performance use 6AN 3 8 to 10AN 5 8 line as required per flow rate requireme
4. ews and Bracket Lock Washers Tighten Bracket Screws between 25 40 in oz of torque Snug do not over tighten screws Install the 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 these style of ports require use of the enclosed 906 O rings for proper sealing reference diagrams below 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 as shown in the diagram below Thread fitting into regulator and tighten between 5 and 15 ft lbs of torque Use Teflon tape or thread sealant on all 1 8 NPT fittings to be used for the Gauge Port and Pressure Reference Port see diagrams below Install fittings or plug as required If pressure reference port is not plumbed to the intake manifold for typical EFI applications port is plumbed to the intake manifold then install the Barbed Fitting supplied and allow fitting to vent to atmosphere do not plumb or plug port Install regulator assembly into vehicle fastening the bracket to the vehicle Attach fuel lines Gauge Port line if external pressure gauge is used in application and Pressure Reference Port line if applicable Boosted applications such as turbo or supercharger
5. his warranty also does not apply to Products upon which repairs have been effected or attempted by persons other than pursuant to written authorization by Manufacturer 3 Exclusive Obligation THIS WARRANTY IS EXCLUSIVE The sole and exclusive obligation of Manufacturer shall be to repair or replace the defective Products in the manner and for the period provided above Manufacturer shall not have any other obligation with respect to the Products or any part thereof whether based on contract tort strict liability or otherwise Under no circumstances whether based on this Limited Warranty or otherwise shall Manufacturer be liable for incidental special or consequential damages 4 Other Statements Manufacturer s employees representatives and or resellers ORAL OR OTHER WRITTEN STATEMENTS DO NOT CONSTITUTE WARRANTIES shall not be relied upon by Buyer and are not a part of the contract for sale or this limited warranty 5 Entire Obligation This Limited Warranty states the entire obligation of Manufacturer with respect to the Products If any part of this Limited Warranty is determined to be void or illegal the remainder shall remain in full force and effect 6 Warranty Service What Does This Warranty Not Cover Any problem that is caused by abuse misuse or an act of God such as a flood is not covered Also consequential and incidental damages are not recoverable under this warranty Some states do not allow the exclusion or l
6. imitation of incidental or consequential damages so the above limitation or exclusion may not apply to you How Do You Get Service In order to be eligible for service under this warranty you MUST return the Warranty Registration card or register on line at www fuelab com warranty within 30 days of purchasing the Product If something goes wrong with your product contact FUELAB at 1 800 541 2345 International customers call 001 217 324 3737 for a Return Authorization Number RMA After receiving your RMA send it postage paid fully insured with a brief written description of the problem to FUELAB Warranty Department 826A Morton Court Litchfield IL 62056 We will inspect your Product and contact you within 72 hours of receipt to give the results of our inspection and an estimate of the labor and or parts charges required to fix the Product if applicable If covered under this limited warranty Manufacturer will repair Product and return it to you at no cost If the Product is NOT covered under this warranty and if you authorize repairs we will return the repaired Product to you COD or prepaid via credit card within 72 hours There is no charge for inspection If return product is found to be free of defects a 25 00 shipping and handling charge will be applied We will return the repaired Product to you COD or prepaid via credit card within 72 hours 105020121 1 RevA Sheet 4of4
7. nts of the vehicle s engine and fuel pump Typical performance EFI applications use a Y block or T fitting to split the output of the fuel pump into one end of each fuel rail for dual fuel rail application The opposite end of each fuel rail is plumbed to the n et Ports of the regulator Plumb the return line back to the fuel tank Use of a 6AN 3 8 return line is typically recommended for this model of regulator See diagram on next page as well as diagram below to identify the ports used on the regulator If only one fuel rail is used for the application use a 6AN plug not supplied and supplied 906 O ring to plug the unused Inlet Port Y block or T fitting not required in this case The fuel line used must handle high pressure The use of fuel line such as stainless steel braided line and AN style fitting connections is recommended The fuel ports two 6AN Inlet Ports and one 6AN Return Port use AN or military style fittings This plumbing standard is commonly used with racing and high performance applications See step 6 on next page for additional information on this port standard A fuel filter with a 60 micron or lower particle rating is required to be used upstream of regulator and downstream from fuel pump to protect it and the fuel injectors from foreign object damage Reference the Schematic Diagram below for filter locations Use of a liquid filled gauge exposed to engine compartment hea
8. nufacturer satisfaction that said defects are covered by this Limited Warranty If the defects are properly reported to Manufacturer within the warranty period and the defects are of such type and nature as to be covered by this warranty Manufacturer shall at its own expense furnish replacement Products or at Manufacturer s option replacement parts for the defective Products Removal of Products from vehicle Vehicle means any automotive bike or marine transportation powered by an internal combustion engine This product is NOT intended or designed for use on aircraft experimental or otherwise shipping to Manufacturer and installation of the replacement Products or replacement parts shall be at Buyer s expense 2 Other Limits THE FOREGOING IS IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE Manufacturer does not warrant against damages or defects arising out of improper or abnormal use or handling of the Products against defects or damages arising from improper installation where installation is by persons other than Manufacturer against defects in products or components not manufactured by Manufacturer or against damages resulting from such non Manufacturer made products or components Manufacturer passes on to Buyer the warranty it received if any from the maker thereof of such non Manufacturer made products or components T
9. rer s Specifications Y Block or T Fitting to Split Flow into Two Fuel Rail System Installation Steps 1 Disconnect the ground terminal from battery and allow the vehicle s engine and exhaust system to cool Relieve fuel system per applicable service manual Follow all Warnings and Cautions written on previous page of these instructions 2 Modify remove or replace other fuel system components as required per established build plan reference notes on previous page and above 3 Use the supplied bracket as a drilling template to mark holes for mounting bracket Choose a location that minimizes exposure to excessive heat near fuel rails Mounting bracket can be modified as required Use clear or colored enamel paint to protect bracket surface after any modification 105020121 1 RevA Sheet 2of4 6AN Inlet Port on each side 10 11 12 Example 6AN Union Fitting Shown Not Supplied Apply light oil onto the threads of the Adjustment Screw Small amounts of air leakage in the adjustment hardware may be present during operation This is a normal operating condition Thread the Adjustment Screw by hand until a slight tension is felt this position is the minimum pressure setting Do not tighten screw any further Pressure is to be adjusted later in these instructions Install the Flat Washer then the Jam Nut Tighten the Jam Nut hand tight for later adjustment Install Bracket to regulator using supplied Bracket Scr
10. t is not recommended as the liquid inside the gauge may exert measurement errors DO NOT plumb gauge port to any gauge mounted inside the vehicle or in passenger compartment A line burst can spill fuel inside passenger compartment and on occupants possibly causing serious injury or death An electric gauge or pressure transducer system is recommended for readings in a passenger compartment Typical EFI V 8 Fuel System Schematic Diagram Follow Fuel Cell Manufacturer s 51502 Regulator Recommendations for Proper a Cell Vent Plumbing Fuel Gauge Shown in Gauge Port Liquid Filled Gauge may have Error Due to Temperature Variations To Engine Intake Manifold Vented Fuel Cell or Fuel Tank Tank must be Plumbed According to Maximum Pump Flow Rate Consult Pump Manufacturer s Specifications and Recommendations 2X Fuel Rails with Injectors Fuel Straining Filter Required Typical Micron Rating 75 150 Fuelab 75 Micron Filter Recommended Straining Filter may be Installed in Fuel Pump Consult Pump Manufacturer s Specifications Fuel Filter with 60 Micron or High Pressure Lower Particle Rating is Required Electric Fuel Pump Fuelab Filter with 6 10 or 40 Micron Rating is Recommended Check Valve Required for Reduced Vehicle Emissions and Improved Engine Starting Valve may be Installed in Fuel Pump Typical OEM Pumps do have this Valve Installed Consult Pump Manufactu
11. t if a permanent gauge is not used Inspect vehicle for any leaks Turn off fuel system and repair any leaks that may be present before continuing When adjusting pressure be sure that fuel pump is operating to monitor pressure Increase pressure by rotating adjustment clockwise Do not thread Adjustment Screw past jam nut within 1 8 Over tightening the adjustment screw can damage the regulator It is recommended 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 After final adjustment of fuel pressure tighten Jam Nut Road test vehicle and retest pressure upon return to ensure accurate adjustment 105020121 1 RevA Sheet 3of4 LIMITED WARRANTY FUELAB a division of FCP Inc having its principal place of business at 826A Morton Court Litchfield IL 62056 USA Manufacturer warrants its FUELAB products the Products as follows 1 Limited Warranty Manufacturer warrants that the Products sold hereunder will be free from defects in material and workmanship for a period of 2 Years from the date of purchase to the original purchaser If the Products do not conform to this Limited Warranty during the warranty period as herein above specified Buyer shall notify Manufacturer in writing or by phone of the claimed defects and demonstrate to Ma
12. will require a hose clamp on barbed fitting to prevent hose from coming loose Use of 3AN or 4AN fitting and line can also be used as a substitute to the barbed fitting Spring Guide Ball may appear to be Off Center Adjustment Adjustment Screw Centers this Part upon Installation Screw Install with Cup Jam Nut toward Regulator Gauge Port Plug 1 8 NPT Pressure Flat Washer can be substitued Reference Port for gauge fitting Engine Vacuum Unique Serial Number Typically for EFI 1 8 Barbed Fitting Identification can be substituted with other fitting Example 6AN Union Fitting Shown g Not Supplied 906 O ring Shown Hy a 2 Prior to Fitting A a installation Rx 1 8 NPT Gauge Port NAN W 6AN Return Line Port fa 906 O ring Example 6AN Nae 8x Bracket Lock Washer 3x Bracket Screw 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 Connect the vehicle s battery 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 Fuel system pressure should read about 25 PSIG use an external gauge for adjustmen
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