file://s:\aps ENGINEERING\

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1 Page 1 of 22 APS GTO Twin Pump Fuel Supply System Installation Guides APS GTO Twin Pump Fuel Supply System - APSGTO-FSS/06 1 Remove the fuel tank assembly as per factory manual. 2 Remove the black plastic tank cover. 3 Remove the tank from the Black plastic cover. 4

2 Page 2 of 22 Disconnect the stock breather hose and stock loom wiring from the fuel pump assembly. 5 Remove the stock fuel pump assembly from the fuel tank. 6 Cut the stock fuel level sensor wires (Red and Black) 6" inches from the sensor. 7

3 Page 3 of 22 Remove the fuel level sensor unit from the stock fuel pump assembly. 8 Remove the stock fuel tank breather vent valve, from the stock fuel pump assembly. 9 Fit the stock fuel tank breather vent valve to the APS pump mounting assembly (Item 25).

4 Page 4 of Slide a 3mmx0.5x16mm cap screw (Item N) into the slot at the rear of the stock fuel level sensor. 11

5 Page 5 of 22 Fit the fuel level sensor to the surge tank bowl using 3mm flat washer (Item M) and 3mm Nyloc nut (Item L). (Note: Hold the cap screw using long nose pliers). 12 Assemble the APS surge tank to the APS pump mounting assembly (Item A) using Button Head bolts, 8mmx1.25x12mm (Item K) and 8mm washers (Item J). (Note orientation of surge tank to pump mounting assembly). 13

6 Page 6 of 22 Solder the stock fuel level sender wires to the same color wires in the loom (Item H), ensuring that the insulation provided is carefully heat shrunk over the connection. 14 Cut the stock fuel supply hose from the standard fuel pump assembly 9" inches from the quick connector.

7 Page 7 of Clip the stock flexible fuel hose to the stock steel fuel line inside the fuel tank (This is now used as a fuel return hose).

8 Page 8 of Insert and lower the pump assembly (Item 25) into the fuel tank. 17

9 Page 9 of 22 Clip the stock fuel tank breather hose onto the APS sender unit (Item 25). 18 Feed the 9" cut stock fuel return hose inside the surge tank. 19 Insert the pump assembly into the fuel tank. 20

10 Page 10 of 22 Remove the stock fuel tank pressure sensor from the stock fuel pump assembly. Remove the stock rubber grommet from the stock pressure sensor. 21 Insert the stock rubber grommet into the APS pump assembly (Item 25). 22 Apply rubber grease and fit the stock pressure sensor to the

11 Page 11 of 22 APS fuel pump assembly (Item 25). 23 Discard the flat washer from the fuel pressure regulator shown. 24 Install a DOWTY washer (Item 3) and replace the locking nut. Turn the adjusting screw in to increase pressure, unscrew to lower pressure. A starting point is 2.5 turns in from finger tight. It is essential that a fuel pressure gauge be connected to the port provided for this purpose at the front of the LHS engine fuel rail. Set the fuel pressure regulation adjusting screw so the gauge shows 58 PSI at idle. Tighten the locking nut. Install a second DOWTY washer (Item 3) and dome nut (Item 4).

12 Page 12 of Install the fuel pressure regulator (Item 1) to the mounting bracket (Item 2) and retain with the two screws supplied with the fuel pressure regulator (Item 1). 26 Install straight adaptors (Item 5) to regulator (Item 1). Install Y adaptor (Item 6) to regulator (Item 1) using Viton O ring (Item 7). 27 Fit a Swivel Barb (Item 13) to the 47" long fuel return hose (Item 11) as well as the Quick Connect Hose End (Item 16) and a clamp (Item 12). 28

13 Page 13 of 22 Fit a Swivel Barb (Item 13) to the 49" long fuel supply hose (Item 10) as well as the Quick Connect Hose End (Item 15) and a clamp (Item 12). 29 Fit Swivel Barbs (Item 14) to the 10.5" and 14" long fuel hoses (Items 8 and 9) and the other ends of the hoses to the Y adaptor (Item 6). Secure with hose clamps (Item 12) at Y piece only. Fit supply (Item 10) and return (Item 11)fuel hoses. 30

14 Page 14 of 22 Unclip and remove wires from the factory plug. 31 Join (solder) the factory wire to the loom (Item 19), heat shrink the insulation tubes and tape joins. 32 Connect the APS Loom (part of Item 19) plug to the pump assembly (Item 25).

15 Page 15 of Install the stock fuel tank breather hose to the new fuel pump assembly. Use tie straps (Item 17) to group together the loom (Item19) and hoses (Item 10 and 11). Connect the 47" fuel return hose (Item 11) to the stock fuel supply tube coming out of the bottom of the stock fuel tank, as this is now the fuel return line. 34 Fit tank to Stock lower tank cover and feed new APS fuel hoses (Items 10 and 11)

16 Page 16 of 22 through the hole. Connect stock fuel tank breather hose. 35 Locate the area shown and mark a circle on the top tank cover at a radius of 4 3/4" inches. Cut circle out of top tank cover. 36 Trim stock tank cover as shown.

17 Page 17 of 22 Fit rubber edging (Item 24) to the modified tank cover. 37 Replace modified tank cover to tank. 38 Re-install the fuel tank assembly into the vehicle and ensure that the fuel supply hose (Item 10) is routed through the stock hole in the boot floor. 39 Connect the 49" fuel supply hose (Item 10) to the stock steel fuel supply pipe running to the front of the car.

18 Page 18 of Working from below, route the fuel pump power supply cable (part of loom, item 19) through the stock rubber grommet in the floor pan. 41 Install the power wire into the relay holder and install the earth plug into the earth plug socket.

19 Page 19 of Install the fuel pressure regulator relay bracket (Item 20) to the rear intrusion brace as shown. 43 Install the relay holder to the relay bracket (Item 20) and retain with a 6mm x 1.0 x 12mm socket head bolt (Item 21) and 6mm x 1.0 NYLOC nut (Item 22). Install the fuel pressure regulator mounting bracket (Item 2) and the fuel pressure regulator (Item 1) to the stock rear intrusion brace. Install the fuel pressure relay (part of loom Item 19) to the fuel pressure relay holder.

20 Page 20 of Overall view of the installation. 45 Route the power cable forward following the stock fuel lines and secure the power cable using 4" plastic tie straps (Item 18).

21 Page 21 of Connect the fuse, earth lead and power wire. Reinstall the stock positive terminal cap. It is essential that a fuel pressure gauge be connected to the port provided for this purpose at the front of the

22 Page 22 of 22 LHS engine fuel rail. Set the fuel pressure regulation adjusting screw as described in step 23 above so the gauge shows 58 PSI at idle.