Parts List
1x Fuel Hanger Assembly (already assembled)
2x Outlet Fittings (as ordered)
1x return fitting (as ordered)
3x Short Teflon Hoses (about 2.125” long)
1x Long Teflon Hose (about 6” long)
7x Pinch Clamps
1x Extra Port Plug (Grub Screw)
3x Ground Eyelets
1x Ground Cable
2x 10-32 x 3/8” Stainless Socket Cap Screws
6x Butt Connectors
Extra wire (for extending fuel pump wiring if necessary)
8x M5x 0.8 Stainless Socket Cap Screws
Sock Filters (If ordered with kit, in quantity ordered)
Fuel Pumps (If ordered with kit, in quantity ordered)
WARNING!!! THE DIFFICULTY OF THIS INSTALLATION IS CONSIDERED TO BE EXTREME! 10 OUT OF 10. IF YOU CAREFULLY FOLLOW THESE STEPS YOU CAN DO THE INSTALLATION, BUT IF YOU HAVE ANY DOUBTS IN BEING ABLE TO DO IT, TAKE YOUR CAR TO A SHOP THAT HAS DONE THE INSTALLATION BEFORE OR WHO HAS THE EXPERTISE TO HANDLE IT. EXPERIENCE IS VITAL.
Step 1
Remove the fuel tank gasket from the factory fuel pump hanger and install onto the PHR hanger.
Step 2
Push the short Teflon fuel lines onto barb fittings on bottom of fuel hat. (Some ports might be plugged from inside the pocket, see later instructions for removing the plug or adding a plug to run different numbers of pumps)
Note: Fuel tubes are now smooth instead of convoluted as shown in picture.
Step 3
Install pinch clamps over hoses (two on each hose) and push pumps into the hoses through the pump holder bracket. The pumps should push all the way until the pump holder bracket keeps them from sliding any further. (obviously the pumps can only alight with the ports in one direction but be careful of twisting the pump and kinking the hose while installing)
Step 4
Using special pinch crimp pliers, pinch the crimp clams to secure the hoses to the barbs on the hat and on the fuel pump. (You can use a set of dikes or wire cutters to crimp the clamps, but they do not crimp evenly using that method. It will work, but a proper set of crimpers is preferred)
Step 5
Remove the factory sending unit from the stock fuel pump hanger. Install the sending unit onto the sending unit bracket. Be sure to use the slot in the bracket to keep it secure. If it is not in the slot, it will fall off. Push the terminals for the sending unit into the sending unit terminals. Secure the wires to the stock sending unit. No connector is necessary and due to the nature of the stock sending unit bracket, it is not possible to have a standard connector. You will see they will hold securely, but while installing the hanger into the fuel tank, care must be taken that these to not get pulled from the sending unit.
Step 6
Cut the connectors from the Walbro 485 Fuel Pumps. You want to keep the wires as long as possible. We remove the connectors because space is very limited inside the tank, and the very bulky connectors make installation very difficult.
Step 7
Using nylon insulated butt connectors, attach the power wires of the fuel pumps to the power wires of the hanger. Secure out of the way using zip ties. These will help when installing the fuel pumps into the tank and keep them out of the way of the sending unit float. Using butt connectors allow the wires to be able to be kept neatly out of the way of the sending unit and help with installation into the fuel tank.
Step 8
Install ring terminal to the ground wire of each pump. Attach the ground wires to the chassis of the fuel hat. (This is why it is important to keep the pump wires as long as possible. The wires are just long enough to reach the ground bolt location. There is extra wire included in the kit in case wires need to be extended but they should reach without extending them.)
Step 9
Attach provided ground wire to the top ground bolt location of the fuel hat (this step could be done after hanger is installed into the fuel tank). After installation of the fuel hat into the tank, the harness should be attached to a good clean ground source.
Step 10