Fuelab 42402 Prodigy Fuel Pump High Power EFI In-Line - Manual (Page 5)

110020274-1, Rev C Page 5 of 6
TROUBLESHOOTING: (cont.)
Installation Steps:
1. Disconnect the ground terminal from battery and allow the vehicle’s engine and exhaust system to cool.
Relieve fuel system pressure per applicable service manual. Follow all Warnings, Cautions and Instructions
written on previous pages of these instructions.
2. Modify, remove or replace other fuel system components as required per established build plan (reference
notes on previous pages and above).
3. Use the supplied brackets attached to the fuel pump, as a drilling template to mark holes for mounting bracket.
Choose a location that minimizes exposure to road hazards and debris, away from engine exhaust pipes, near
fuel tank or cell. Note position and plumbing requirements as stated earlier in these instructions.
4. Install the fuel fittings (not supplied). The threads used on these Fuel Ports are not tapered or pipe threads.
Do not use Teflon
®
thread tape or thread sealant on these threads, as this can cause leakage or introduce
debris into the fuel system. Fittings to be used with these style of ports require use of the enclosed -910 O-
rings for proper sealing. Use light oil to lubricate the O-rings just prior to installation. Install the O-rings onto
the fuel fitting first. Position the O-ring in the thread relief of the fitting. Thread fitting into regulator and tighten
between 5 and 15 ft·lbs of torque.
5. Inspect fuel system for any contact of fuel lines or wires with other components that can cause chafing or
rubbing. Secure all components and fuel lines. Ensure that moving components of vehicle are clear.
6. Connect the vehicle’s battery. Perform initial priming: The Fuel pump may require priming during initial
operation and for moment after depletion of fuel from fuel tank or cell. This action can be accomplished by
removing fuel line from fuel rail (downstream of fuel pump and filters), allowing the fuel line to empty fluid into
fuel safe container. Operate fuel pump until fuel exits fuel line. Attach fuel line back to the fuel rail after priming
fuel pump. After tightening connection, verify leak-free operation while checking fuel rail pressure. If fuel
pressure is not high enough, repeat priming procedure to ensure that fuel pump is receiving fuel from tank.
Turn on fuel pump (typically by bypassing fuel pump relay) without engine operating. ECU or engine
management computer may be controlling the relay. The ECU may only operate pump for a few seconds each
time ignition switch is set to on. The pump will have to operate several seconds (30+) to prime and drive air out
of the fuel system.Reattach fuel rail line. Start fuel system and inspect for leaks. Fuel system pressure should
read about 25 PSIG (use an external gauge for adjustment if a permanent gauge is not used). Inspect vehicle
for any leaks. Turn off fuel system and repair any leaks that may be present before continuing.
7. When adjusting pressure, be sure that fuel pump is operating to monitor pressure. Fuelab recommends to use
a “baseline” pressure reference when adjusting the pressure (adjusting the pressure with engine off or Pressure
Reference Line unhooked). The vehicle’s engine may not produce consistent vacuum during idle to have
repeatable readings.
8. After final adjustment of fuel pressure, tighten Jam Nut. Road test vehicle, and retest pressure upon return to
ensure accurate adjustment. After installation of this fuel pump, verify flow capacity to ensure safe levels of
flow, particularly with reduced levels of pump speed. Having insufficient flow capacity can result in an engine
lean-out condition that can cause severe engine damage. Collecting a given amount of fuel (as measured by
weight or volume) over a measured amount of time can be used to determine capacity. Collect fuel flow from
the return line to measure the amount of fuel capacity at a given operating pressure. A 20+ ampere capacity
battery charger may be used to simulate the charging system of the vehicle while engine is off. If using an
adjustable fuel pressure regulator, for boosted applications, simulate boost by raising the fuel pressure by the
amount of expected maximum boost pressure. Performing these tests will give greater accuracy for capacity
tests.
Problem Possible Cause Possible Solution
Not building up fuel
pressure. • Incorrect
fuel system initial
priming procedure.
• Loose inlet fuel fittings or leaking
plumbing on inlet side.
Repeat procedure for proper priming. If condition
continues, check all plumbing upstream (on inlet
side) of fuel pump.
Fuel pressure drops
off under heavy
engine load,
particularly in
higher gears. • Incorrect wiring of speed control
as specified in wiring Examples 1
through 5.
• Loose terminal or wiring.
• Insufficient
fuel capacity.
Make sure pump is operating at full speed while
under high engine load. If condition continues,
upgraded pump capacity is required.
Leakage of fuel at
inlet or outlet fuel
ports.
• Improper type of fitting used.
If leakage is occurring between end caps of pump
and sleeve of pump, contact Fuelab immediately for
repair or replacement. If leakage occurs at fitting, be
sure that the proper fitting style is used (AN o-ring
seal type ONLY!). Pipe threaded style fittings are
NOT to be used.