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1. red wire and one of the yellow 10 ring connectors and the supplied yellow 3 8 ring connector 4 8 Ensure that electrical components and wires are connected properly See Figure 4 1 and are clear of any moving suspension or drivetrain components and any exhaust components Protect wires from abrasion and road obstructions or debris SUPPLIED 2 16 or 18 GA SU ae RELAY WIRE XOT CLEAN CHASSIS 12 VDC FROM OEM ne ee GROUND FUEL PUMP iss tes s OO es ir OR RED WIRE lerci GROUND FROM OEM VERE NOT SUPRDTED 30 a7 FUEL PUMP BLK WIRE SUPPLIED RED 19 GA WIRE 4 a FUEL PUMP SUPPLIED SUPPLIED ane RED 19 GA WIRE BLACK 10 GA WIRE 12 VDC CLEAN CHASSIS SUPPLIED 30 AMP GROUND CIRCUIT BREAKER CIRCUIT BREAKER TO BE INSTALLED AS CLOSE TO BATTERY AS POSSIBLE FROM BATTERY Figure 4 1 Section 5 Final Checks and System Start up 5 1 Ensure that any spilled gasoline and any gasoline soaked shop towels are cleaned up and removed from the vicinity of the vehicle 5 2 Carefully lower the car onto the ground 5 3 Fill the fuel tank with gasoline and check for any leaks in the system if any leaks are found repair immediately CAUTION While performing the following steps if any fuel leaks are detected immediately turn the ignition OFF remove any spilled fuel and repair the leak s before proceeding 5 4 Reconnect the battery and turn the ignition to the ON position WITHO2. ring 2 ea yellow female blade connector 7 ea AN 10 o ring 5 ea yellow 10 stud ring connector 2 ea p n 15606 AN 06 cutoff union 1 ea yellow 3 8 stud ring connector 1 ea p n 15607 AN 08 cutoff union 6 ea tie wraps 5 ea p n 15608 AN 10 cutoff union 20 ft AN 10 stainless steel braided line 2 ea p n 15201 Holley Dual feed bowl to AN 06 5 ft AN 06 stainless steel braided line 12 ea tie wraps 16 ft AN 08 stainless steel braided line 2 ea AN 10 90 degree hose end 2 ea AN 10 straight hose end 2 ea AN 08 90 degree hose end 2 ea AN 06 90 degree hose end 2 ea AN 06 straight hose end Warning The included Aeromotive fuel pump is not compatible with alcohol based fuels or fuel additives This kit assumes you have a sumped fuel tank or fuel cell with accommodations for an AN 10 Supply line and an AN 08 return line Fuel tank pickups will not work properly with Aeromotive fuel systems and will be detrimental to your fuel systems life If your fuel tank is not sumped we recommend having your fuel tank sumped by a qualified professional No fuel rails are provided with this kit your fuel rails must have accommodations to accept AN 08 hose ends in order to install this kit properly The following steps are typical of most installations Section 1 Fuel Pump Installation Section 2 Fuel Regulator Installation and Fuel Line Plumbing Section 3 Fuel Line Hose End Installation Section 4 Electrical Installation Section 5 Final Chec
3. through the fuel tank shield and through the fuel pump mounting holes Install four flat washers and nuts on the bolts and tighten Inspect the inside of the plastic fuel tank shield for any sharp edges that could puncture the fuel tank If any sharp edges are found correct before proceeding 1 11 If you are mounting the fuel pump in some other fashion secure the fuel pump to the mounting surface using four Ya bolts nuts and lock washers not provided Note Be sure to route all fuel lines clear of any moving suspension or drivetrain components and any exhaust components Protect fuel lines from abrasion and road obstructions or debris 1 12 Using two of the supplied AN 10 hose ends as a guide measure the length of AN 10 steel braided line needed to connect your fuel tank sump or fuel cell outlet to the fuel pump filter assembly inlet 1 13 Cut and assemble the steel braided hose and hose ends as shown in Section 3 1 14 Using the above steel braided hose assembly connect one end to the outlet of the fuel tank sump and the other end to the fuel pump filter assembly inlet and tighten Note It is recommended that a fuel shut off valve be installed between the fuel tank outlet and the fuel pump filter assembly inlet these valves are available from most popular racing fitting manufactures Aeroquip Earl s Goodridge Russell etc 1 15 In vehicles engine compartment locate a suitable mounting location for the supplied f
4. AEROMOTIVE Part 17242 ya Generic Fuel System Kit AEROMOTIVE INSTALLATION INSTRUCTIONS CAUTION Installation of this product requires detailed knowledge of automotive systems and repair procedures We recommend that this installation be carried out by a qualified automotive technician Installation of this product requires handling of gasoline Ensure you are working in a well ventilated area with an approved fire extinguisher nearby Extinguish all open flames prohibit smoking and eliminate all sources of ignition in the area of the vehicle before proceeding with the installation When installing this product wear eye goggles and other safety apparel as needed to protect yourself from debris and sprayed gasoline WARNING The fuel system is under pressure Do not open the fuel system until the pressure has been relieved Refer to the appropriate vehicle service manual for the procedure and precautions for relieving the fuel system pressure Aeromotive system components are not legal for sale or use on emission controlled motor vehicles This kit contains the following parts 1 ea fuel pump wiring kit 1 ea p n 11101 Pump 1 ea 3ft length of 10 ga Black wire 1 ea p n 12304 Filter 100 Micron SS 1 ea 25ft length of 10 ga Red wire 1 ea p n 12301 Filter 10 Micron Paper 1 ea 30 amp circuit breaker 1 ea p n 13204 Fuel Pressure Regulator 1 ea 30 amp automotive relay 2 ea AN 06 o ring 2 ea blue female blade connector 1 ea AN 08 o
5. E INC LIMITED WARRANTY This Aeromotive Product with proof of purchase dated on or after January 1 2003 is warranted to be free from defects in materials and workmanship for a period of one year from the original date of purchase No warranty claim will be valid without authentic dated proof of purchase This warranty is to the original retail purchaser and none other and is available directly from Aeromotive and not through any point of distribution or purchase If a defect is suspected the retail purchaser must contact Aeromotive directly to discuss the problem possible solutions and obtain a Return Goods Authorization RGA if deemed necessary by the company Please call 913 647 7300 and dial option 3 for the technical service dept All returns must be shipped freight pre paid to the company and with valid RGA before they will be processed Aeromotive will examine any product returned with the proper authorization to determine if the failure resulted from a defect or from abuse improper installation misapplication or alteration Aeromotive will then at it s sole discretion return repair or replace the product If any Aeromotive product is determined defective buyer s exclusive remedy is limited in value to the sale price of the good In no event shall Aeromotive be liable for incidental or consequential damages Aeromotive expressly retains the right to make changes and improvements in any product it manufactures and sells at
6. UT starting the car After several seconds check the fuel pressure If there is no fuel pressure turn the ignition key to the OFF position wait one minute return the ignition to the ON position and recheck the fuel pressure Repeat this ignition OFF and ON procedure until the fuel pressure gauge registers fuel pressure 5 5 With the fuel pressure gauge registering fuel system pressure check for fuel leaks throughout the entire fuel system If any fuel leaks are found turn the ignition key to the OFF position remove any spilled fuel and repair the leak before proceeding 5 6 Once the fuel pressure gauge registers fuel system pressure and there are no fuel leaks start the engine and adjust the regulator to the desired fuel pressure Turning the adjustment screw clockwise will increase fuel pressure Typical regulators are set at approximately 5 6 psi The fuel pressure adjustment range for this regulator is 3 15 psi 5 7 Once the desired fuel pressure is achieved tighten the regulator adjustment jam nut and attach the vacuum line 5 8 Test drive the car to ensure proper operation and re check the fuel system for leaks If any leaks are found immediately discontinue use of the vehicle and repair the leak s Thanks for purchasing another quality product designed engineered and manufactured in Kansas City USA AEROMOTIVE INC 7805 Barton Street Lenexa KS 66214 phone 913 647 7300 fax 913 647 7207 www aeromotiveinc com AEROMOTIV
7. any time These changes and improvements may be made without notice at any time and without any obligation to change the catalogs or printed materials Aeromotive expressly retains the right to discontinue at any time and without notice any Aeromotive product that it manufactures or sells This warranty is limited and expressly limits any implied warranty to one year from the date of the original retail purchase on all Aeromotive products No person party or corporate entity other than Aeromotive shall have the right to determine whether or not this Limited Warranty is applicable to any Aeromotive product authorize any action whatsoever under the terms and conditions of this Limited Warranty assume any obligation or liability of any nature whatsoever on behalf of Aeromotive under the terms and conditions of this Limited Warranty This Limited Warranty covers only the product itself and not the cost of installation or removal This Limited Warranty is in lieu of and expressly excludes any and all other warranties expressed or implied This Limited Warranty gives you specific legal rights and you may also have other rights which vary from state to state Aeromotive Inc 7805 Barton Street Lenexa KS 66214 Phone 913 647 7300 Fax 913 647 7207
8. fuel pressure regulator 2 4 Install the supplied AN 08 o rings on the cutoff side of the AN 08 cutoff union fitting if not already installed and install in the AN 08 port located on the bottom of the supplied fuel pressure regulator 2 5 Install one of the supplied AN 10 o rings on the cutoff side of the AN 10 cutoff union fitting if not already installed and install in the AN 10 port located on the front of the supplied fuel pressure regulator 2 6 Place the crush rings on the dual feed carburetor to AN 06 adapter fittings Thread each of the two fittings into each of the carburetor float bowls and tighten If you are using a carburetor other then a dual feed style you will have to make alternate accommodations for an AN 06 fuel supply line 2 7 Starting from each of the carburetor float bowls plan a route to run an AN 06 supply line from each float bowl to each side of the fuel pressure regulator Cut the two supply lines to the determined length and install the AN 06 hose ends as detailed in Section 3 Note Be sure to route all fuel lines clear of any moving suspension or drivetrain components and any exhaust components Protect fuel lines from abrasion and road obstructions or debris 2 8 Starting from the outlet of the fuel pump filter assembly plan a route to run an AN 10 supply line from fuel pump filter assembly to the fuel this line should be run along the same route you planned to run the return line in step 1 16 C
9. iring harness going to the fuel tank to relay terminals 85 and 86 using two of the supplied blue female blade connectors See Figure 4 1 Below Note Be sure to route all electrical wires clear of any moving suspension or drivetrain components and any exhaust components Protect wires from abrasion and road obstructions or debris 4 3 Find a suitable location for mounting the supplied circuit breaker For optimal circuit protection the circuit breaker needs to be mounted as close to the battery as possible 4 4 Connect terminal number 30 on the relay to the circuit breaker by using the supplied red 10 ga wire one of the yellow female blade connectors on the relay end of the wire and one of the yellow 10 ring connectors on the circuit breaker side of the wire Note Be sure to route all electrical wires clear of any moving suspension or drivetrain components and any exhaust components Protect wires from abrasion and road obstructions or debris 4 5 Connect terminal number 87 on the relay to the positive terminal on the fuel pump This is accomplished by using the supplied red 10 ga wire one of the yellow female blade connectors on the relay side of the wire and one of the yellow 10 ring connectors on the fuel pump side of the wire 4 6 Connect the negative terminal on the fuel pump to a clean chassis ground using the supplied black 10 ga wire and two yellow 10 ring connectors 4 7 Connect 12VDC to the circuit breaker using the supplied
10. ket from the rest of the hose end fitting 3 3 lnsert hose in the socket with a twisting and pushing motion until the hose is fully seated in the socket 3 4 Using a grease pencil marker or tape mark the location of the hose in relation to the hose socket that you just installed 3 5 Using a light oil lubricate the inside of the hose and hose end mating parts 3 6 Carefully thread the hose end onto the hose socket making sure that the hose does not push out of socket by observing the mark you placed on the hose in step 3 4 3 7 Using a properly sized wrench complete threading the two components together The maximum allowable gap between the two fitting components is 030 inches 3 8 Inspect the hose for push out by comparing the mark you made on the hose in step 3 4 to the hose end socket location 3 9 Clean all debris from exterior and interior of hose 3 10 All lines should be tested to twice their operation pressure prior to use Section 4 Electrical Installation 4 1 Find a suitable place to mount the supplied relay the relay is typically mounted by the OEM fuel pump wiring connector Never mount the relay inside of the fuel tank or next to fuel tank vents Ensure the relay and any associated parts are clear of the exhaust any moving suspension or drivetrain components and any possible road obstructions or debris 4 2 Attach the OEM fuel pump wires These typically are the red and black wires from the OEM w
11. ks and System Start up Fuel Pump Template Typical hose end to fitting connection Do not connect hose end to cutoff side of union Connect hose end to 37 degree flare side of union Hose End Typical o ring sealed port connection O ring sealed AN style port O ring Install on union fitting between back of threads and face of hex nut Typically the cutoff side of the union is used as the o ring sealed side leaving the 37 degree flare side for your hose end connection In some cases both sides of the union utilize an o ring seal For example in this kit a union connects the port of the fuel pump and filter Section 1 Fuel Pump Installation 1 1 Once the engine has been allowed to cool disconnect the negative battery cable and relieve the fuel system pressure 1 2 Raise the vehicle and support it with jack stands 1 3 Referring to the appropriate vehicle service manual for instructions drain disconnect any electrical and fuel component connections 1 4 In the kit find two AN 10 cutoff union fittings and four of the AN 10 o rings Install each of the four o rings on each end of the two AN 10 cutoff union fittings 1 5 Install each of the two fittings into each end of the provided Aeromotive fuel pump 1 6 Noting the appropriate flow directions install the provided fuel filter Aeromotive p n 12301 on the fuel pump outlet and the other fuel filter Aeromotive p n 12304 on the fuel pump inlet If y
12. ou get the two filters mixed up the 12304 filter will have a 100 micron stainless steel filter element inside where as the 12301 will have a 10 micron paper filter element inside 1 7 Install one of the supplied AN 10 o rings on the cutoff side of the AN 10 cutoff union fitting if not already installed and install on the inlet side of the pump filter assembly 1 8 Install one of the supplied AN 10 o rings on the AN 10 cutoff side of the AN 10 cutoff union fitting and install the fitting on the outlet side of the pump filter assembly 1 9 Find a suitable mounting location for the above pump filter assembly Typical mounting locations include mounting the fuel pump to the fuel tank shield or mounting to the inside of the frame rail The fuel pump should be mounted as close to the fuel tank as possible and as low as possible Using the fuel pump as a guide or using the pump mounting template mark the four pump mounting holes Ensure there are no obstructions behind the mounting surface and drill four 4 mounting holes Note Be sure to route all fuel lines clear of any moving suspension or drivetrain components and any exhaust components Protect fuel lines from abrasion and road obstructions or debris 1 10 If you are using the plastic fuel tank shield for mounting your fuel pump secure the fuel pump to the plastic fuel tank shield by installing four carriage bolts not included from the inside of the fuel tank shield
13. uel pressure regulator 1 16 Starting from the determined regulator mounting location in the engine compartment plan a route to run an AN 08 return line back to the fuel tank or fuel cell return port and measure the required length Cut the return line to the determined length and install the two supplied AN 08 hose ends as detailed in Section 3 Note Be sure to route all fuel lines clear of any moving suspension or drivetrain components and any exhaust components Protect fuel lines from abrasion and road obstructions or debris 1 17 Thread one end of the AN 08 return line onto the AN 08 return line accommodations of your fuel tank or fuel cell and tighten 1 18 Make any line or electrical adjustments necessary to clear the vehicles exhaust suspension and drivetrain components Section 2 Fuel Regulator Installation and Fuel Line Plumbing 2 1 In the vehicle s engine compartment mount the supplied fuel pressure regulator in the location established in step 1 15 Using the supplied mounting bracket as a template mark the bracket mounting holes and drill to accept a 10 screw 2 2 With the bracket attached to the regulator mount the bracket and regulator to the vehicle using two 10 screws nuts and lock washers not provided 2 3 Install two of the supplied AN 06 o rings on the cutoff side of two AN 06 cutoff union fittings if not already installed and install in each of the AN 06 ports located on the sides of the supplied
14. ut the supply line to the determined length and install the AN 08 hose ends as detailed in Section 3 Note Be sure to route all fuel lines clear of any moving suspension or drivetrain components and any exhaust components Protect fuel lines from abrasion and road obstructions or debris 2 9 Using the above steel braided hose assembly connect one end to the outlet of the fuel pump filter assembly Keeping both the supply line and return line from the Aeromotive fuel tank together secure both lines to the vehicle along the predetermined route using the supplied tie wraps Once both lines are secure connect the supply line to the fuel pressure regulator and the return line to the bottom of the regulator and tighten Note Be sure to route all fuel lines clear of any moving suspension or drivetrain components and any exhaust components Protect fuel lines from abrasion and road obstructions or debris 2 10 Once the regulator is installed attach a suitable fuel pressure gauge not supplied to the 1 8 NPT port on the fuel pressure regulator Section 3 Fuel Line Hose End Installation CAUTION When assembling this product wear eye goggles and other safety apparel as needed to protect yourself from debris and sharp edges 3 1 Wrap hose with masking tape at desired cutoff length Cut hose through masking tape squarely to desired length using a cut off machine or a fine tooth hacksaw Remove the masking tape 3 2 Unthread the hose soc
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