Aeromotive 17242 User Manual

AEROMOTIVE

Part # 17242

Generic Fuel System Kit

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 3ft length of 10 ga. Black wire
1 ea 25ft length of 10 ga. Red wire
1 ea 30 amp circuit breaker
1 ea 30 amp automotive relay
2 ea blue female blade connector
2 ea yellow female blade connector
5 ea yellow #10 stud ring connector
1 ea yellow 3/8” stud ring connector
6 ea tie-wraps
20 ft AN-10 stainless steel braided line
5 ft AN-06 stainless steel braided line
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.

:

1 ea p/n 11101 Pump
1 ea p/n 12304 Filter 100 Micron SS
1 ea p/n 12301 Filter 10 Micron Paper
1 ea p/n 13204 Fuel Pressure Regulator
2 ea AN-06 o-ring
1 ea AN-08 o-ring
7 ea AN-10 o-ring
2 ea p/n 15606 AN-06 cutoff union
1 ea p/n 15607 AN-08 cutoff union
5 ea p/n 15608 AN-10 cutoff union
2 ea p/n 15201 Holley Dual feed bowl to AN-06
12 ea tie-wraps

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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 Checks 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.

Typical o-ring sealed port connection:

O-ring sealed AN style port

O-ring

(Install on union fitting between back o

threads and face of hex nut.)

Hose End

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 you 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 ¼” 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 ¼” carriage bolts (not included) from the inside of the fuel tank shield, 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

¼” 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.