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1. 39 Prep the new tank by making all the necessary connection feed return vent and electrical before placing tank in vehicle In most cases once the tank is placed in the vehicle these connection will not be accessible For electrical wiring refer to Figure 2 1 Note Tank vent must be at least 6 above the top of the tank if a roll over valve is used highly recommended 40 Reinstall the fuel tank in the vehicle In some cases it may be necessary to space the fuel tank down to allow additional clearance for the new pump outlet top plate and fittings 1 2 thick foam material is provided and should be divided and installed at the top of the tank on either side between the tank and the trunk floor to help space the fuel tank down if necessary Additional fabrication may be necessary to gain clearance in extreme cases 41 Now route the feed and return line under the vehicle and secure them to the chassis It s recommended to install a post filter between the fuel pump and the engine see Aeromotive part 12301 12321 Place the filter in a location that is clear of Suspension and exhaust system components and easy to get to for servicing 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 42 The pictures below are typical regulator installations for EFl setups with Aeromotive Bypass Regulator P N 12. the fuel pump 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 fuel pump OFF wait one minute then turn the fuel pump ON and recheck the pressure Repeat this fuel pump OFF and ON procedure until the fuel pressure gauge registers pressure or you detect a fuel leak It may be necessary to loosen the fuel line fitting at the pressure regulator to bleed off excessive air in the system Tighten any fuel line fittings which where loosened and insure that any spilled fuel is cleaned up and removed from the vicinity of the vehicle 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 connections to determine the cause Once the fuel pressure gauge registers pressure start the engine The gauge on the fuel pressure regulator should register between 3 and 12 psi for carb and 35 60 for EFI Now adjust the fuel pressure regulator to the desired setting 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 AEROMOTIVE INC LIMITED WARRANTY This Aeromotive Product
3. 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 any time These changes and improvements may be made wit
4. 3109 Figures 1 1 amp 1 2 FEED LINE FROM FUEL PUMP RETURN LINE TO TOP OF TANK Fuel Rails with inlet outlets Figure 1 2 43 Use the figure below for a single carb installation with Aeromotive Bypass Regulator P N 13204 Figure 1 3 Feed to carb Feed from fuel pump Return to top of tank Single carb setup Figure 1 3 44 45 A6 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 Connect electrical power 12 VDC to the pump Make sure you use stranded insulated copper wire in the sizes shown with matching crimp type connectors for all connections CAUTION The pump must not be connected directly to the battery Connect the Aeromotive fuel pump as shown in the following diagram 20 AMP NORMALLY 12 VDC POWER FUEL PUMP CED PELAT SOURCE WHICH IS SUPPLY WIRE Q Q Q 16 or 18 GA CONTROLED WITH 16 or 18 CA CLEAN CHASSIS MAIN POWER SWITCH FUEL PUMP GROUND SWI TCH 12 GA MINIMUM 12 GA MINIMUM 12 VDC m FROM BATTERY 12 GA MTNTMUM 20 AMP FUSE CLEAN CHASSIS AEROMOTIVE FUEL PUMP GROUND Figure 2 1 CAUTION While performing the following steps if any fuel leaks are detected immediately turn the fuel pump OFF remove any spilled fuel and repair the leak s before proceeding Turn
5. 7 AEROMOTIVE Part 18688 amp 18689 ya Phantom Fuel Pump Baffle System AEROMOTI VE For Tank Depths 6 11 INSTALLATION INSTRUCTIONS Patent Pending WARNING Always be aware of flammable situations Drilling and grinding can be potential ignition sources Extinguish all open flames prohibit smoking and eliminate all sources of ignition in the area of the vehicle and workspace before proceeding with the installation Ensure you are working in a well ventilated area with an approved fire extinguisher nearby WARNING Installation of this product requires modification to a fuel tank failure to satisfy all safety considerations will result in fire explosion injury and or loss of life to yourself and or others WARNING Mechanical and hydraulic lifting devices can tip over or lower accidentally due to incorrect maneuvering or technical errors A falling object can cause injury and or loss of life to yourself and or others When working under the vehicle always use stands and ensure that the ground or floor is stable and level Never crawl under a vehicle which is only supported by a jack 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 CAUTION CAUTION When installing this product always wear safe
6. H 13 5 V 60 psi 189 LPH 13 5 V Continuous Operating Range 5 psi 65 psi 13 5 V 5 psi 65 psi 13 5 V Pump internal By Pass Pressure 105 psi 80 psi Current Draw Aeromotive Commonly Used Fittings 15606 AN 06 ORB to AN 06 Flare Inlet outlet vent fitting For AN 06 fuel lines 15649 AN 06 ORB to AN 08 Flare Inlet outlet vent fitting For AN 08 fuel lines 15609 AN 10 ORB to AN 06 Flare fuel filter fitting For AN 06 fuel lines 15610 AN 10 ORB to AN 08 Flare fuel filter fitting For AN 08 fuel lines Aeromotive AN 10 Fuel Filter P N s 12301 Red 10 micron Fuel Filter 12304 Red 100 micron Fuel Filter 12321 Black 10 micron Fuel Filter 12324 Black 100 Micron Fuel Filter 12351 Chrome 10 micron Fuel Filter 12354 Chrome 100 micron Fuel Filter 12335 Red 40 micron Fuel Filter 12331 Black 100 micron Fuel Filter w Shutoff Valve 12305 Fuel Filter Bracket Aeromotive Electrical Components 16301 Fuel Pump Wiring Kit 16306 Fuel Pump Speed Controller Aeromotive system components are not legal for sale or use on emission controlled motor vehicles The following steps are typical of most installations 1 Once the engine has been allowed to cool disconnect the negative battery cable and relieve the fuel system pressure referring to the appropriate vehicle service manual for the procedure and precautions for doing so 2 Raise the vehicle on stable level ground and support it with jack stands 3 Referring to the appro
7. e tank is corrugated or has ribs on the desired mounting surface the included gasket will compress and form to the ribs up to 1 4 deep In extreme cases where the ribs are deeper than 14 or oddly shaped the use of a fuel resistant sealant such as Dow Corning 730 fluorosilicone RTV or additional fabrication may be necessary Do not use silicone gasket sealant as it is not fuel resistant 34 With the fuel pump hanger is fully assembled and the gasket in place ease the pump hanger assembly into the baffle assembly inside the fuel tank Rotate the billet fuel pump hanger assembly to orient the fuel line and vent connections in the desired orientation and drop the hanger onto the retaining ring studs 35 Press down firmly on the top of the pump assembly to compress the gasket Start two of the 10 24 lock nuts on a pair of studs 180 degree apart Tighten these two nuts until the remaining studs are approximately 1 4 exposed 36 With the remaining 8 studs exposed approximately 1 4 place one of the 10 white nylon sealing washers on each of the studs followed by a 10 24 locking nut 37 Remove the first two lock nuts used to help compress the gasket Place one of the 10 white nylon sealing washers on each of these two studs followed by reinstalling the 10 24 locking nut 38 With all 10 studs now having a 10 white nylon sealing washer and a locking nut slowly tighten using a crisscross pattern until the gasket forms to the tank surface
8. he fuel pump location Measure the foam baffle assembly from the bottom black rubber part up and mark the assembly 1 longer than the determined tank depth If the tank was 6 deep mark the foam baffle assembly to be 7 long Using a bread knife or fine tooth hacksaw blade carefully cut the foam baffle to the desired length 23 Install the fuel pump retainer ring into the fuel tank from the inside The C shape allows the ring to be inserted through the smaller hole to the inside of the tank and the studs pushed up through the holes drilled in steps 11 15 24 Place the installation ring over the retaining ring studs that now protrude from the top of the tank With the foam baffle fully inserted into the bladder cup Compress the baffle assembly and insert it through the installation ring into the tank being careful not to cut the assembly or your hands on the tank edge Once the baffle assembly is in the tank manipulate it until it s centered within the opening 25 NOTE COMPLETE THIS STEP ONLY IF YOU PLAN ON USING A RETURNLESS FUEL SYSTEM where the ECU uses PWM to control fuel pressure In this case you must drill a 1 32 hole thru the pipe plug indicated below If you are planning on using a traditional return style fuel system please skip this step If you are unsure what your system requires please contact your EFI system manufacturer or Aeromotive for assistance If using a returnless system where the ECU controls fue
9. he orientation of the fuel pump outlet cap how you would like to route the electrical and fuel lines Note Ensure that you mount the fuel pump at the deepest possible area of the fuel tank 7 Ifthe top of the tank is corrugated or has ribs on the desired mounting surface the included gasket will compress and form to the ribs up to 1 4 deep for extreme cases where the ribs are deeper or oddly shaped the use of a fuel resistant sealant such as Dow Corning 730 fluorosilicone RTV or additional fabrication may be necessary Do not use silicone gasket sealant as it is not fuel resistant 8 Using the fuel pump retainer ring C shaped part with 10 threaded studs as a guide determine the fuel pump mounting location avoiding the areas previously identified If the top of the tank is corrugated or has ribs further positioning will be required Noting the location of the tank ribs position the fuel pump retainer ring such that it will be balanced across the ribs Note that the fuel pump retainer ring will be on the inside of the fuel tank so position it across the ribs that protrude into the tank Next rotate the fuel pump retainer ring such that none of the studs fall on the side walls of the ribs Once you have double check the selected mounting position mark the center Avoid having mounting hole through side wall of rib a gees Sam iS ts AN mm o O A 9 With the center of the fuel pump location marked and everyt
10. hing double checked use metal cutting hole saw to create a 3 1 4 hole in the top of the tank 10 11 12 13 14 15 16 17 18 19 20 21 22 Place the included installation ring over the 3 1 4 hole so the raised register drops into it Now rotate the ring until the bolt pattern is in the predetermined alignment If the tank is corrugated or has ribs rotate or clock the installation ring to ensure that none of the holes on the bolt pattern would have to be drilled into the side walls of the ribs With the installation ring correctly clocked in place use the included 2 drill bit and drill one of the bolt pattern holes Place one of the included 10 24 x 2 1 2 screws in the above hole to help hold the index ring for further drilling With the installation ring still in place drill a second hole directly across 180 degrees from the first Place the second 10 24 x 2 1 2 screw in the above second hole With the installation ring still held in place by the first two alignment screws drill the remaining 8 holes Remove the installation ring and two alignment screws Using the fuel pump retainer ring align the studs with the newly drilled holes and check for proper fit Remove any burrs that where created during the drilling operations above Carefully clean any debris from inside the fuel tank a good shop vac can be very helpful here Using a tape measure determine the depth of the tank at t
11. hout 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
12. l pressure Drill a 1 32 diameter hole thru the center of brass 1 8 NPT pipe plug 26 Install fuel pump strainer and the foam sleeve on the fuel pump Position the fuel pump on the fuel pump hanger assembly such that from the bottom of the outlet cap to the bottom of the fuel pump strainer is equal to the fuel tank depth Mark the bracket and the black outlet hose so they may be cut to the necessary lengths Remember take the time to measure twice and cut once Note Failure to position the fuel pump strainer on the bottom of the basket assembly will potentially starve the pump for fuel when fuel tank level is low yielding poor drivability and reduced pump performance 27 Cut the black outlet hose to the desired length 28 Using a metal cutting saw cut the bracket to the desired length removing enough at the bottom to ensure that the end of the bracket will not contact the fuel pump strainer 29 Using the small hose clamp attach the black outlet hose to the fuel pump and tighten 30 Using the two larger hose clamps attach the pump to the pump bracket and tighten The clamps should be positioned in the notches of the bracket 31 Plug the electrical connector s into the pump and tuck the wire out of the way for kit p n 18689 the positive connector is the 250 wide terminal and the negative terminal is 188 wide 32 Install the provided gasket onto the threaded studs on the fuel pump retaining ring 33 If the top of th
13. priate vehicle service manual for instructions drain disconnect any electrical and fuel component connections and remove the OEM fuel tank The removal of the vehicles exhaust system may be necessary for fuel tank removal This Aeromotive Phantom Fuel Pump System is intended to be installed into a NEW fuel tank that does NOT and has NEVER contained fuel If you choose to install this product into a fuel tank that has had fuel introduced to it proceed at your own risk The fuel tank must be professionally cleaned to remove all traces of any combustible fluids Failure to properly clean and remove all combustible fluids from the fuel tank will result in injury or loss of life to yourself and or others 4 With the new cleaned fuel tank on your preferred work surface start to determine the desired pump mounting location on top of the fuel tank by identify mounting areas to avoid Avoid areas of the tank where level sending unit float arm or float are present Also avoid areas where the fuel filler neck may protrude inside the fuel tank Never mount the fuel pump on the side or bottom of the fuel tank Avoid areas around filler necks and level sending unit floats 5 Secondly locate and avoid areas of the top of the fuel tank that might contact the bottom of the vehicle frame rails supports or floor pan 6 Now that you have identified the areas on the fuel tank to avoid you can narrowed this down further by identifying t
14. seal with o rings these ports are NOT PIPE THREAD and utilize NO THREAD SEALANT The fuel pump used in this tank is either the Aeromotive Stealth 340 part 11142 for kit 18688 or the Aeromotive Stealth part 11137 for kit 11189 To insure proper pump function and life we strongly recommend the following e Utilize AN 06 EFI and AN 08 carb size high pressure fuel lines fittings and o rings for all connections from the fuel tank to the engine e Install a 10 micron post filter Aeromotive p n 12301 or 12321 e Install a remote mount rollover valve It must be mounted in a vertical position and mounted as high or higher than your filler tube e Fuel pump wiring should be 10 gauge wire and triggered with a relay rated at a minimum of 20 amps Aeromotive fuel pump wiring kit 16301 e A return style regulator must be used with the exception of running an ECU that supports a returnless systems where the ECU controls fuel pressure via PWM Aeromotive p n 13105 13109 or 13129 for EFI 13204 for carb 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 Pump Specifications Po 18688 Kit Pump 11142 18689 Kit Pump 11137 Outlet pressure typical flow 10 psi 408 LPH 13 5V 10 psi 272 LPH 13 5 V 40 psi 340 LPH 13 5 V 40 psi 215LPH 13 5 V 60 psi 284 LP
15. ty glasses and other appropriate safety appeal A drilling operation will cause flying metal chips Flying metal chips can cause eye injury wear Safety glasses 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 Careless installation of this product can result in damge to the product injury or loss of life to yourself and or others Parts Included Fuel Pump 11142 for 18688 or 11137 for 18689 2ea_ Ring Terminal Fuel Pump Sleeve 11142 2ea Ring Terminal Cap Fuel Pump Strainer 1ea Hose Clamp Fuel Pump Hanger Assembly 2ea Pump Clamp Fuel Pump Foam Baffle Assembly 10ea 10 24 Nylon Locking Stainless Steel Nut Gasket 1 2 Thick 10ea 10 Nylon Washer Retainer Ring lea 2 Drill 221 dia Installation Ring 2ea 10 24 x 2 1 2 Machine Screw 30in 1 Wide x 1 2 thick Foam Spacer Tools Needed 3 1 4 Metal Cutting Hole Saw Tape Measure Drill Bread Knife or Straight Slot Screwdriver Hacksaw blade 3 8 Socket and Ratchet AN 06 Outlet Port Pump Power Terminals AN 06 Vent Port AEROMOTIVE AN 06 Return Port If using a returnless system where the ECU controls fuel pressure Drill a 1 32 diameter hole thru the center of brass 1 8 NPT pipe plug The enclosed Aeromotive fuel pump assembly utilizes an o ring sealed AN 06 style feed return and vent ports These ports
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