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Barb’s has won 8 Harley-Davidson Bar & Shield Awards, and has become NJ’s number one dealer of new and used Harley-Davidson’s. You can be sure to be greeted in their pressure free environment. Visit http://www.barbshd.com
The installation of the APR FSI Fuel Pump onto any VAG 2.0T FSI engine should be carried out using all of the factory recommended installation procedures and precautions. The notes, recommendations, and precautions in this document are intended as a supplement to those already provided by VAG. This entire document must be read and understood before attempting to install your APR FSI Fuel pump. WARNING: Direct Injection FSI fueling systems run at very high pressures. The pressure in the fuel lines must be relieved prior to removal of the fuel pump to prevent serious bodily injury. Please consult a factory-approved repair manual (i.e. Bentley manual) for the proper procedures and precautions.To ensure that your vehicle is ready for the installation of the APR FSI pump, you must be aware of the condition of the mechanical components that drive the pump in your 2.0T FSI equipped vehicle. This is critical to the operation and longevity of your vehicle and your APR FSI Fuel Pump. The high-pressure FSI fuel pump used in the 2.0T FSI equipped vehicles is mechanically driven by the intake camshaft and is therefore directly tied to the vehicle valve train assembly. In addition, there is a low-pressure feed pump at the fuel tank of your vehicle and a fuel filter with integral pressure-regulator that are important to the operation of the APR FSI pump. To add to the complexity, there are many auxiliary sensors and pressure relief valves that are all critical to the proper operation of the direct injection fueling system on your vehicle. It is the responsibility of the customer and/or the installer to ensure that all the vehicle components driving the FSI fuel pump are in good working order and are not in a state of excessive wear or failure prior to the installation of the APR pump. Volkswagen of America, Inc. has released a Technical Service Bulletin (TSB) stating that there is a known problem concerning premature wear of the intake camshaft lobe and camshaft follower that drive the FSI high-pressure fuel pump. This wear has been known to cause fuel delivery issues and fuel rail pressure fluctuations. If this wear goes unchecked, wear can also begin on the base of the FSI high-pressure fuel pump. In some cases, this wear can result in a complete failure of the intake camshaft which may result in extensive damage to the engine valve train, head, and other related components. The published TSB describes the proper method for inspecting your vehicle for this type of wear and APR, LLC Tech Article “APR FSI Fuel Pump Installation Notes, Recommendations, and Precautions”;
The following pertains primarily to Mallory COMP Pumps equipped with Gerotor style pump systems, but also applies to many other fuel systems. BASIC INFORMATION The Mallory Gerotor style COMP Pumps are more forgiving than vane style pumps, but it is still important to insure they are properly mounted and receive clean fuel. The correct mounting position is even with or below the tank and preferably behind or next to the fuel tank. All electric pumps push fuel far better than they can pull (suck) fuel. Make sure that a low restriction filter is between the tank and the pump. A 40-micron element it sufficient to protect the pump from contamination such as dirt, rust, fuel cell foam, etc. Mallory has them available that will screw directly into the pump itself. Electric pumps need a clean and stable power source. Run a minimum of 12 gauge wires to the pump if it is relatively close to the power source. Longer runs should utilize 10 gauge wire instead. With a trunkmounted battery, we recommend that you use a relay to allow for short power wires to be run. Do not pull power from a common terminal, especially if the ignition is wired to the same terminal.
The best location for mounting any electric fuel pump is the rear of the vehicle. The inlet and outlet of the pump must be mounted below the lowest point of the tank. This is necessary to allow for an adequate fuel supply. The pump is designed to push fuel and not designed to suck fuel out of the tank. It needs to be gravity-fed or if it’s pulling from the top of the tank, it needs to develop a siphon feed to the pump. The pump should be mounted on the chassis, in a vertical position with the pump motor on top. Avoid exposure of the pump and fuel lines to moving parts and to any hot areas, such as the exhaust. The pump should not be mounted in a closed area, such as the vehicle’s trunk. Follow the steps below for mounting the pump. 1-800-345-4545 jegs.com WARNING! THE PUMP MUST BE LOCATED SO THAT INTERFERENCE BETWEEN THE VEHICLE’S BODY AND ITS CHASSIS MOVEMENT IS AVOIDED. THE PUMP AND ITS CONNECTING HOSES MUST NOT BE SUBJECTED TO LOW GROUND CLEARANCE, WHERE ANY FLYING ROCKS OR ROAD DEBRIS CAN CAUSE DAMAGE. FAILURE TO AVOID THESE HAZARDS WILL LEAD TO PUMP DAMAGE, WHICH COULD RESULT IN FIRE, PROPERTY DAMAGE, SERIOUS INJURY, AND/OR DEATH.
ROTARY FUEL PUMPS FGA PUMP: IN-LINE GEROTOR TYPE Flow rate >200 lph (53 gph) @ 300 kPa (43 psi) Pressures to 500 kPa (75 psi) Current: as low as 3.5 amps @ 300 kPa (43 psi) @ 13 volts > 0 H O lift 5” 2 Operating temperature: -40°~+155° F Hot fuel losses as low as 25% Contamination filter @ < 30 micron >3,000 hour life Da tr4 mm (.5) i e: 2 me 16 ” Integral pressure relief valve Mounting: vertical (outlet on top) to horizontal OPTIONS: o Carbon commutator o Outlet check valve o Inlet fittings o Outlet fittings o Electrical connectors o Mounting kit FGB PUMP: IN-TANK GEROTOR TYPE Flow rate to 250 lph (66 gph) @ 300 kPa (43 psi) Pressures to 900 kPa (130 psi) Current: as low as 1.0 amp @ 300 kPa (43 psi) @ 13 volts > 0 H O lift 5” 2 Operating temperature: -40°~+155° F Hot fuel losses as low as 20% Contamination filter @ < 30 micron >3,000 hour life Da tr3 mm (.”t i e: 1 me 12)o 3 mm (.”d p n i o mo e 9 15) e e d g n d l n Integral pressure relief valve Mounting: vertical (outlet on top) to horizontal OPTIONS: o Carbon commutator o Outlet check valve o RFI suppression o Inlet fittings o Outlet fittings o Electrical connectors o Inlet filter FTB PUMP: IN-TANK TURBINE TYPE Flow rate to 240 lph (63 ghp) @ 300 kPa (43 psi) Pressures to 500 kPa (75 psi) Current: as low as 3.4 amps @ 300 kPa (43 psi) @ 13 volts Operating temperature: -40°~+155° F Hot fuel losses as low as 5% Contamination filter @ < 30 micron >3,000 hour life Da tr3 mm (.5)o3 mm i e: 7 me 14 ”t 9 (.4)s memo e p mpc a e 15 ”(o dl u s h mb r @ 52mm (2.05") Walbro Worldwide Headquarters 7400 N. Oracle Road, #310 Tucson, Arizona 85704-6342 USA Telephone (520) 877-3000 Fax (520) 877-3006 Email: email@example.com We enable machines that make life better! Integral pressure relief valve Mounting: vertical (outlet on top) to horizontal OPTIONS: Carbon commutator Outlet check valve RFI suppression Outlet fittings Electrical connectors Inlet filter Flex fuel compatibility Walbro North America North American Sales Office Email: firstname.lastname@example.org Walbro Japan Asian Sales Office Email: email@example.com Walbro Europe European Sales Office Email: firstname.lastname@example.org Walbro China China Sales Office Email: email@example.com www.walbro.com Rotary 5/2013
Incomplete review of all the information in this document can cause errors. Read the entire Service Bulletin to make sure you have a complete understanding of the requirements In response to field reports of leaking Hartzell Engine Technologies’ (HET’s) fuel pump, Lycoming Engines requires replacement of all fuel pumps identified in Tables A and B with a verified fuel pump of the same part number. Lycoming Engines requires that the fuel pumps be replaced because fuel leaks at the fuel pump valve assembly have been observed from the overboard drain system. These leaks could be due to assembly issues associated with the valve assembly. Table A identifies suspect fuel pumps by part number and serial number that shipped on Lycoming engine models. Table B identifies suspect fuel pumps by part number and serial number that shipped as spare parts. Required Action for Fuel Pumps Shipped with Engines 1. Look for fuel leakage along the outlet of the overboard drain system. 2. Look at your engines. Review engine serial numbers and fuel pump serial numbers against Table A and Table B (in the event a spare fuel pump in Table B was installed on the engine). If you find an engine serial number and/or fuel pump serial number identified in Tables A or B on one of your engines, obey the warranty terms in this Service Bulletin. 3. Review fuel pump serial numbers in your spare parts inventory against Table B. If you find a fuel pump serial number identified in Table B, obey the warranty terms in this Service Bulletin.
Aeromotive 340 Stealth Fuel Pump Applications Guide 11169 *New Make / Model Year Pump Part No. Integra 1994-2001 Aeromotive 340 Stealth 11142 NSX 1991-2000 Aeromotive 340 Stealth 11141 RSX 2002-current Aeromotive 340 Stealth 11142 Chrysler/Dodge FWD 1984-1990 340 Stealth Pump Force Induction 11140 Dodge Stealth T/T 1991-1997 Aeromotive 340 Stealth 11141 Eagle Talon 1995-1998 AWD&FWD Aeromotive 340 Stealth 11142 340 Stealth Pump AWD Turbo 340 Stealth Pump FWD Turbo 11141 11142 1995-1998 AWD&FWD Aeromotive 340 Stealth 11142 1990-1994 AWD Turbo FWD Turbo Aeromotive 340 Stealth Aeromotive 340 Stealth 11141 11142 Lightning Pick Up 1999-2000 340 Stealth Pump 11142 (2) F150 1997-1998 1999-2004 340 Stealth Pump 340 Stealth Pump 11142 11142 Mustang 1985-1997 340 Stealth Pump except 96-97 Cobra 11140 Mustang Cobra 1996-1997 Aeromotive 340 Stealth 11142 Probe GT 1988-1992 1993-1997 Aeromotive 340 Stealth Aeromotive 340 Stealth 11141 11142 *Crown Vic/Mercury Marauder 2003-2004 Aeromotive 340 Stealth 11142 ACURA Chrysler/Dodge/Plymouth Turbo 1990-1994 Plymouth Laser Turbo Ford Truck Ford General Motors Buick Grand National / Regal 1982-1987 Aeromotive 340 Stealth 11169 Chevrolet Camaro 5.0L & 5.7L 1985-1992 Aeromotive 340 Stealth 11169 Corvette 5.0L & 5.7L 1982-1996 Aeromotive 340 Stealth 11169 GM Cars & Trucks 1985-1992 Aeromotive 340 Stealth 11169 Chevrolet & GMC Trucks 305 (5.0L) & 350 (5.7L) TBI engines* *Not for use with dual tanks 1987-1997 Aeromotive 340 Stealth 11169 1982-1995 Aeromotive 340 Stealth 11169 Pontiac Firebird 5.0L & 5.7L 1985-1992 Aeromotive 340 Stealth 11169 Fiero 2.8L 1985-1986 Aeromotive 340 Stealth 11169 GMC Cyclone 1991-1992 Aeromotive 340 Stealth 11169 Typhoon 1992-1993 Aeromotive 340 Stealth 11169 Saturn SC,SL,SW 1997-2002 Aeromotive 340 Stealth 11142 Accord 1990-1993 1994-1997 1998-2002 Aeromotive 340 Stealth Aeromotive 340 Stealth Aeromotive 340 Stealth 11141 11142 11142 Civic 1988-1991 1992-2000 Aeromotive 340 Stealth 11142 CRX 1989-1991 Aeromotive 340 Stealth 11141 Prelude 1985-1987 1992-1996 1997-2001 Aeromotive 340 Stealth Aeromotive 340 Stealth 11141 11142 1997-2001 Aeromotive 340 Stealth 11142 Miata 1994-1997 1999-2005 Aeromotive 340 Stealth Aeromotive 340 Stealth 11142 11142 MX6 1988-1992 1993-1997 Aeromotive 340 Stealth Aeromotive 340 Stealth 11141 11142 Protégé 1990-1991 1995-1998 Aeromotive 340 Stealth Aeromotive 340 Stealth 11141 11142 RX7 1986-1988 1989-1992 1993-1995 Aeromotive 340 Stealth Aeromotive 340 Stealth Aeromotive 340 Stealth 11141 11141 11141 S/T trucks (S-10, S-15, Sonoma, Blazer, Envoy) Honda Hyundai Tiburon Mazda 323 1986-1991 Aeromotive 340 Stealth 11141 3000 GT Twin Turbo 1991-1997 Aeromotive 340 Stealth 11141 Eclipse 1995-1998
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. To use this pump in your vehicle’s fuel system, you must do the following: A by-pass style fuel pressure regulator must be used in the system. Utilize AN-10 size high pressure fuel lines, fittings and o-rings for all connections from the fuel tank pickup to the fuel pump. To ensure proper fuel pump performance and longevity, mount pump level with or lower than the bottom, and as close to the tank, as possible. Install a 12304 pre-filter and 12301 post filter. If you are using a stock fuel tank, install a reservoir sump in the bottom-rear of your fuel tank. Exercise extreme caution and follow all manufacturers’ recommendations when installing a reservoir sump. (Sump part # 18650) Tank/Fuel cell must have at least a ½” tank vent. If you choose not to install a reservoir sump, then you must install a high flow capacity fuel tank pickup (9/16” to 5/8” inner tube diameter). Installing pickup tube instead of a reservoir sump may shorten the fuel pump life and cause drivability problems. When using a pickup, you should maintain at least ½ tank of fuel to avoid possible engine lean-out and/or fuel pump damage. For long term driving applications where continuous run times exceed 30 minutes and fuel capacity is less then 10 gallons, Aeromotive recommends the installation of a Fuel Pump Speed Controller to maintain lower fuel temperatures in the tank. See Aeromotive Fuel Pump Speed Controller 16306.
! ! ! WARNING: BATTERIES NORMALLY PRODUCE EXPLOSIVE GASES. THEREFORE, DO NOT ALLOW FLAMES, SPARKS OR LIGHTED SUBSTANCES TO COME NEAR THE BATTERY. WHEN CHARGING OR WORKING NEAR A BATTERY, ALWAYS SHIELD YOUR FACE AND PROTECT YOUR EYES. ALWAYS PROVIDE VENTILATION. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY ! ! ! ! ! ! WARNING: KEEP OUT OF THE REACH OF CHILDREN. BATTERIES CONTAIN SULFURIC ACID. AVOID CONTACT WITH SKIN, EYES OR CLOTHING. ALSO, SHIELD YOUR EYES WHEN WORKING NEAR THE BATTERY TO PROTECT AGAINST POSSIBLE SPLASHING OF THE ACID SOLUTION. IN CASE OF ACID CONTACT WITH THE SKIN OR EYES, FLUSH IMMEDIATELY WITH WATER FOR A MINIMUM OF 15 MINUTES AND GET PROMPT MEDICAL ATTENTION. IF ACID IS SWALLOWED, CALL A PHYSICIAN IMMEDIATELY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY ! ! !
Reference: 06-04 Chevrolet Malibu V6-3.5L 06-04 Chevrolet Malibu L4-2.2L 2006 Chevrolet Malibu V6-3.9L 09-03 SAAB 9-3 L4-2.0L NHTSA Campaign ID Number 11E009000 Airtex has determined a potential product safety issue involving E3592M and E8489M fuel pump modular assemblies. While no safety-related occurrences have been reported in the field, Airtex is taking steps to avoid any potential issues. These part numbers are purchased from the OE supplier. Airtex was notified by the OE supplier that an out-of-tolerance component could potentially cause an issue with the operation of the pump. This recall not only affects Airtex, but many other aftermarket and original equipment suppliers. To avoid any potential issues, it is necessary that you and your customers contain and return all E3592M and E8489M fuel pump modules marked with manufacturing date codes 200 through 081.Fuel pumps must be returned freight collect to the address listed below within 30 days. To ensure proper shipment tracking of the affected product, please call 800-880-3056 to obtain an RGA number. Make reference to Fuel Pump Safety Recall FP030911-1 in correspondence, packing and shipping documents. 407 West Main Street Fairfield, IL 62837 800.880.3056 www.airtexproducts.com