AEROMOTIVE Part # 11102 INSTALLATION INSTRUCTIONS
Contents
1. Check all electrical connections Connect power wires to proper terminals Plumb the fuel pump in the proper orientation Debris may have entered the fuel pump and locked it up Contact Aeromotive No Contact Aeromotive Is the fuel pressure regulator you are using a by pass style Are you using a sumped fuel tank or a fuel cell Is the fuel line between the fuel tank fuel cell a minimum of 9 16 ID or AN 10 Is the fuel pump mounted at or below the half tank fuel level Does the fuel filter on the inlet side of the pump have a 100 micron filtration rating and have a min of 60 in area Yes Are the fuel filters in the system been clean or new Yes Are you driving the vehicle for periods of time greater then 30 minute with less the 10 gallons of fuel in the tank Yes A by pass style regulator is required for proper operation of this product For EFI we recommend Aeromotive p n 13101 or 13109 For carb applications we recommend Aeromotive p n 13204 A sumped fuel tank or fuel cell is required for proper product performance refer to Aeromotive tech bulletin 802 Pickup tubes vs sumped tanks for specific details Clean high flow inlet plumbing is required for proper pump operation a min of 9 16 ID or AN 10 fuel line is required on the pump inlet side The fuel pump must be mounted such that it has a good gravity feed to insure proper p2. AEROMOTIVE Part 11102 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 The enclosed Aeromotive fuel pump utilizes an o ring sealed AN 12 style inlet and outlet ports these ports are NOT PIPE THREAD and utilize NO THREAD SEALANT Maximum continuous operating pressure should not exceed 70 psi A high capacity fuel filter must be installed between the fuel tank and pump inlet We recommend an Aeromotive P N 12302 Call us for info To use this pump in your vehicle s fuel system we strongly recommend the following Gravity feed the pump by mounting it lower than and as close as possible to the fuel t
3. able place on the vehicle chassis to mount the Aeromotive fuel pump Make sure the location will accommodate the pump mounting bolts will position the pump lower than the fuel tank is clear of the exhaust is clear of any moving suspension or drivetrain components and will keep the pump clear of road obstructions or debris 6 Using the pump as a template mark and drill four mounting holes to accept 14 bolts Mount the fuel pump using four 14 bolts nuts and lock washers 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 7 Connect the fuel tank sump to the fuel filter inlet and the fuel filter outlet to the fuel pump inlet 8 Connect the fuel pump outlet to the vehicle s fuel rails in the engine compartment Make sure you use high pressure 200 psi minimum fuel line for this connection 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 9 There are several ways to connect electrical power to the pump depending on your fuel injection system Make sure you use stranded insulated copper wire in the sizes shown with matching crimp type connectors for all connections 10 Attach the OEM fuel pump wires the aftermarket ECM fuel pump wires or your fuel pump swit
4. ank If you are using a stock fuel tank install a reservoir style sump in the bottom rear of your fuel tank Exercise extreme caution and follow all manufacturer s recommendations when installing a reservoir style sump Utilize AN 12 size high pressure fuel lines fittings and o rings for all connections from the fuel tank pickup to the fuel rails in the engine compartment Failure to follow the above recommendations may result in fuel leakage bursting of the fuel lines poor vehicle performance and or decreased fuel pump life Improper installation will void all warranties for this product Aeromotive system components are not legal for sale or use on emission controlled motor vehicles Specifications Model 11102 Port Sizes Inlet amp Outlet AN 12 The following steps are typical of most installations 1 Once the engine has been allowed to cool relieve the fuel system pressure and disconnect the negative battery cable 2 Raise the vehicle and support it with jack stands 3 Referring to the appropriate vehicle service manual for instructions remove the OEM fuel pump 4 Install an after market fuel tank sump kit per the manufacturer s instructions Note Failure to mount the pump lower than and close to the fuel tank may cause the pump to run dry resulting in extreme pump wear Make sure the pump is located lower than and as close as possible to the fuel tank so that the pump is always supplied with fuel 5 Find a suit
5. ch wires as shown in the following diagram 11 12 12 VDC POWER SOURCE WHICH IS Pa MAIN POWER SWITCH FUEL PUMP WIRE AND SWITCE SWITCH OR 30 AMP RELAY 16 or 18 GA CLEAN CHASSIS GROUND 1 OR GROUND FROM OEM FUEL PUMP 12 VDC FROM OEM FUEL PUMP OR AFTERMARKET ECM 16 or 18 GA FUEL PUMP TERMINALS 10 GA WIRE rms ma CLEAN CHASSLS 30 AMP FUSE OR GROUND CIRCUIT BREAKER CIRCULT BREAKER TO BE INSTALLED AS CLOSE TO BATTERY AS POSSIBLE 12 VDC FROM BATTERY Attach a suitable fuel pressure gauge to the fuel system schrader valve fuel rail or fuel pressure regulator Ensure that any spilled fuel and any fuel soaked shop towels are cleaned up and removed from the vicinity of the vehicle CAUTION While performing the following steps if any fuel leaks are detected immediately turn the ignition to OFF remove any spilled fuel and repair the leak s before proceeding 13 14 15 16 17 Turn the ignition to ON without starting the engine allow the pump to run for several seconds and check the fuel pressure If there is no pressure turn the ignition to OFF wait one minute then turn the ignition to ON and recheck the pressure Repeat this ignition OFF and ON procedure until the gauge registers pressure or you detect a fuel leak If no pressure is registered on the gauge after running the pump for several seconds and you have found no leaks check all fuel and electrical c
6. ent and 12 inlet and outlet fittings The 12302 is also recommended for the 11104 EFI Eliminator pump and our new 11105 belt drive pump try 400gph or 2700Ib hr of fuel delivery at 100psi Though Genuine Aeromotive Filters may be somewhat more expensive than the off brand options you simply must compare apples to apples They say a picture is worth a thousand words Real Filter a pa OQ M CEOR se Elements need Biers AT a only apply Surface area Above are various versions of 100 micron fuel filters elements Note the top element is the Aeromotive 100 micron element P N 12604 as found the fuel filter assembly P N 12304 Note the various filters all have billet housing with AN connections and can be disassembled for inspection and cleaning Also note that all are sold and recommended as appropriate pre filters Of course it s obvious by this comparison image that there s more to a filter than the micron rating a billet housing or even AN Connections It should be equally clear that surface area the amount of filter material available for fuel flow is not at all related to micron rating but a major key to a filters flow capacity All these filters may be fine well made assemblies and perhaps they are suitable for use with various fuel pumps on various engines However excepting the very top element which is there for comparison none of the above belong in any system featuring an Aeromo
7. eromotive expressly retains the right to make changes and improvements in any product it manufactures and sells at 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. ne damage can result Lesson Don t combine high flow efficient fuel pumps with poor flowing inlet filters Don t use fuel lines smaller than the pump ports Don t use fuel tank pick ups or tank outlets smaller than the line Catastrophic fuel starvation and fuel pump damage caused by improper inlet filtration i e AA Typical off brand billet filter Note the pretty aluminum housing with the postively tiny sintered bronze filter element Far less than 100 micron porosity and maybe 2 surface area What about a fine filter They are also necessary but must be installed on the outlet side of your Aeromotive fuel pump never on the inlet Options include the Aeromotive 10 micron replaceable element fabric filter assemblies P N 12301 and P N 12310 and the new high flow 40 micron cleanable element stainless steel filter assembly P N 12335 Given the alcohol content found in today s pump gas it is now necessary to frequently monitor and service any downstream fuel filters in use Because they cannot be cleaned keep a spare 10 micron element on hand for immediate service to eliminate engine fuel starvation and drivability problems when they become heavy clogged All Aeromotive pumps except the Pro Series EFI pump may use the Aeromotive filter 12304 with 10 inlet and outlet fittings and 100 micron stainless steel element The Pro Series EFI pump 11102 requires filter 12302 with larger stainless steel elem
9. onnections to determine the cause Once the fuel pressure gauge registers pressure start the engine The fuel pressure gauge should register between 40 and 70 psi If you have installed an adjustable fuel pressure regulator adjust it to the desired setting For maximum fuel system performance we recommend using an Aeromotive adjustable fuel pressure regulator call us for info Shut the engine off Using suitable clips and other mounting hardware secure the newly installed fuel lines and electrical wires by attaching them to the vehicle chassis Carefully lower the vehicle to the ground Test drive the vehicle to insure 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 913 647 7300 fax 913 647 7207 Do you have voltage at the pump terminals Is the terminal connected to 12 V and the terminal connected to the battery ground cable Is the fuel line going to the engine compartment connected to the same side of the fuel pump as the power terminals Do you have a 100 micron fuel filter installed on the inlet side of the fuel pump Yes Contact Aeromotive Fuel System Troubleshooting Pump does not run at all Pump performs poorly or runs intermittently
10. riming and a long service life The fuel filter on the inlet side of the fuel pump is required to be rated at 100 micron and have no less then 60 in filtering area For detailed information see Aeromotive tech bulletin 101 titled Inlet Filtration Insure that all fuel filters are clean or new proper filters are an inexpensive cure to a lot of fuel system problems Refer to Aeromotive tech bulletin 102 titled Post Pump Filtration As the fuel level falls in your tank it is being recirculated at an increasing rate allowing less time for fuel cool down in these cases it is recommended to use a Fuel Pump Speed Controller we recommend Aeromotive n n 16306 Aeromotive Inc Technical Bulletin 101 From Aeromotive Technical Department Date 10 10 2011 Re Fuel Filtration Selecting the correct filter to prevent lean out and pump failure STOP If you are selling or installing a fuel filter on the inlet of an Aeromotive fuel pump be certain you do not use a filter that causes more problems than it solves For pump inlet filtration use only Aeromotive 100 micron P N 12304 12302 or an acceptable equivalent see specifications below Do not install the Aeromotive P N 12301 or 12310 filter with 10 micron fabric element on the inlet of any Aeromotive fuel pump they are however perfect for use on the outlet of the pump and this is the only location for which they are recommended All 100 micron Fuel Filter
11. s are NOT created equal Aeromotive 100 micron filter cartridge Stainless Steel pleated construction Over 60 square inches of surface a Off brand 100 micron filter returned with an A1000 pump the customer claimed was defective is it any mystery why the pump failed to perform Nopel You may run any brand of filter you choose on your car just be certain that it meets the following requirements The filter element used on the inlet side of any Aeromotive fuel pump may be no finer than 100 micron no number smaller than 100 with a surface area of 60 square inches or more Any filter element not meeting these criteria may fail to flow the full volume of the pump resulting in both vehicle drivability and pump reliability problems Aeromotive fuel pumps are engineered to be efficient and can create both high outlet pressure and high inlet vacuum The boiling temperature of any liquid varies with pressure For example the engine cooling system is purposely designed to pressurize the coolant in order to raise the boiling point So how does this apply to fuel delivery When a fuel pump has to pull through a restriction to get fuel from the tank a vacuum develops which lowers the fuel s boiling temperature cavitating the fuel and turning it from liquid into vapor Bottom line Inlet restrictions create vacuum which causes cavitation which in turn causes vapor lock and fuel pump damage Of course drivability problems and even engi
12. tive fuel pump and certainly not any car boat truck etc that features an engine worthy of such a pump AEROMOTIVE 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 A
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