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
Install sock filters to the bottom of the fuel pumps.
Step 11
Install the return hose onto the return port hose of the siphon valve (also know as Jetpump). This port is the one that is a straight pass through on the valve. This hose must be submerged for the siphon valve to operate. (The siphon valve is critical to pull fuel from the non-fuel pump side of the tank to the pump side of the tank. Without this operating correctly, the vehicle will run out of fuel around 1/3 to 1/4 tank of fuel left.)
Point the hose away from the fuel pump inlets to keep the fuel from cavitating due to the flow of the return fuel.
Another note about the siphon pump: The siphon pump has an orifice that is of importance in size. It this orifice is important to provide the jet that creates the siphon effect that creates suction from the other side of the tank, BUT it restricts the amount of fuel that can be returned to the tank. This can be a problem in regulating fuel pressure at idle if running multiple pumps at idle. Therefore it is important that these pumps be staged so not all three (or two) pumps run during low fuel consumption (idle). As the motor starts to make power and consumes fuel, less fuel is then retuning to the tank, and you can power on the other pumps in stages. This will keep return flow low and allow for proper fuel pressure regulation.
Step 12
ONLY PERFORM THIS STEP IF INSTALLING 3 WALBRO 485 FUEL PUMPS. IT IS NOT REQUIRED IF RUNNING ONE OR TWO PUMPS
Using pliers or other tool pry up on the opening of the fuel tank. Be careful to make a nice clean even bend. This is the seal surface to the tank and any wrinkles or unevenness will cause the fuel tank to leak. This is an important step to be able to get 3 pumps into the tank at one time. It is best to do small steps.
Step 13
Attach the siphon hose from inside the tank to the siphon valve port. (this port is the one that attaches to the side of the siphon valve)
Step 14
First, slip the sending unit float into the tank. Then, one pump at a time carefully slide the large part of the fuel pump under the lip of the fuel tank. This is not easy to do. It takes some work and the edge of the tank must be pried up as in the previous step if installing 3 pumps. The sending unit and the siphon valve hoses will also cause this to be difficult.
Be patient. At first try, you will think this is impossible. But they do go. They will fit.
Installing only two pumps is significantly simpler, and it is not even necessary to bend the lip of the tank, but it is still difficult to try to get everything in the tank at one time.
Step 15
Slowly work the fuel hanger into the fuel pump, gently pushing hoses and sending unit. It is important to make sure the sending unit float does not get tangled or hung up on anything in the tank and it is also important that the sending unit wires are not accidentally pulled from the unit.
After fully inserting the hanger will align like in the third picture above. The holes are slotted to allow some movement.
Finally, bolt the hanger into place using the M5 bolts, attach feed and return lines, and wire accordingly. Sending unit colors should match vehicle colors in the stock 5 pin connector. Power wires should be installed through relays and controlled by and aftermarket ECU.
PLUG REMOVAL OR INSTALLATION FOR 1, 2 or 3 PUMPS
Step 1
Remove three bolts from top of hanger. This will allow the pump bracket and pocket cover to be removed from the hat.
Step 2
Once pocket is removed from the hat, take note of the inside of the pocket cover as shown above.
Step 3
Remove or install any plugs as necessary to install the correct number of pumps. Use a high quality sealant when installing plugs to prevent leaks. DO NOT USE TEFLON TAPE.
Step 4
Reinstall the pocket cover.
Step 5
Reinstall the 3 bolts, securing the pocket cover and pump bracket to the top hat.
IMPORTANT: make sure orientation of the fuel pump bracket is correct so that the pump outlets align properly with the inlets to the the hanger.