Aeromotive 19102 Phantom Series Direct Drop In Dual Fuel Pumps Instruction Manual
- June 13, 2024
- AEROMOTIVE
Table of Contents
AEROMOTIVE
Part # 19101, 19102, and 19103
Phantom Fuel Pump / Baffle System
For 1999-2002 Camaro/Firebird Drop In Modules
INSTALLATION INSTRUCTIONS
Patent 8,783,287
19102 Phantom Series Direct Drop In Dual Fuel Pumps
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!
When installing this product always wear safety glasses and otheappropriate
safety appeal. A drilling operation will cause flying metal chips Flying metal
chips can cause eye injury.
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 damage to the product, injury or loss of life to yourself and/or
others.
Parts Included
1ea Fuel Pump (11140)
1ea Fuel Pump Strainer
1ea Fuel Pump Hanger Assembly
1ea Fuel Pump Foam Baffle Assembly
2ea AN-6 ORB Port Plugs
2ea Male Blade Connector (22-18 GA Red)
2ea Ring Terminal (10-12 GA Yellow for Pump)
2ea Ring Terminal (22-16 GA Red for Level Sensor
4ea Ring Terminal Cap
2ea 10-24 Nyloc Nuts
Tools Needed:
Wire Cutters
Wire Strippers/Crimpers Small 3/8” Wrench
Lock Ring Remover Tool
Parts Required: (Not Included)
1 – OEM Replacement Fuel Pump Gasket
PN: GM – 25167743 or Equivalent
The enclosed Aero motive fuel pump assembly utilizes an o-ring sealed AN-06
style feed, return and vent ports. These ports seal with o-rings; these ports
are NOT PIPE THREAD and utilize NO THREAD SEALANT.
The fuel pump used in this tank is the Aero motive Stealth 340 (part # 11140).
To ensure proper pump function and life, we strongly recommend the following:
- Utilize AN-06 or AN-08 (EFI) or AN-08 (carb) size high pressure fuel lines, fittings and o-rings for all connections from the fuel tank to the engine, including the supply and return lines.
- Install a 10 micron post-filter (Aero motive p/n 12301 or 12345).
- Install a remote-mount rollover valve. It must be mounted in a vertical position and mounted as high or higher than your filler tube.
- Fuel pump wiring should be 10 gauge wire and triggered with a relay rated for a minimum of 30 amps (Aero motive standard fuel pump wiring kit P/N 16301 or the Deluxe HD wiring kit P/N 16307).
- A return style or bypass regulator must be used (Aero motive p/n 13105, 13109, 13129, or 13303 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
| 19101 Kit (Pump #11140)| 19102 Kit (Pump 2x #11140)| 19103 Kit (Pump #11145)
---|---|---|---
Outlet pressure/typical flow:
Continuous Operating Range:
Pump internal By-Pass Pressure:
Current Draw:| 10 psi / 408 LPH @ 13.5 V
40 psi / 340 LPH @ 13.5 V
60 psi / 284 LPH @ 13.5 V
5 psi – 65 psi @ 13.5 V
105 psi
13 amps @ 40 psi| 10 psi / 408 LPH @ 13.5 V
40 psi / 340 LPH @ 13.5 V
60 psi / 284 LPH @ 13.5 V
5 psi – 65 psi @ 13.5 V
105 psi
2x 13 amps @ 40 psi| 0 psi / 454 LPH @ 13.5 V
40 psi / 430 LPH @ 13.5 V
60 psi / 381 LPH @ 13.5 V
5 psi – 65 psi @ 13.5 V
120 psi
15.3 amps @ 40 psi
Aero motive Commonly Used Fittings
15689 AN-06 ORB to AN-06 AN Flare 90 Degree (Inlet/outlet/vent fitting)
15606 AN-06 ORB to AN-06 Flare (Inlet/outlet/vent fitting)
15649 AN-06 ORB to AN-08 Flare (Inlet/outlet/vent fitting)
15609 AN-10 ORB to AN-06 Flare (fuel filter fitting)
15610 AN-10 ORB to AN-08 Flare (fuel filter fitting)| For AN-06 fuel lines
For AN-06 fuel lines
For AN-08 fuel lines
For AN-06 fuel lines
For AN-08 fuel lines
---|---
Aero motive AN-10 Fuel Filter P/N’s
12301 Red 10-micron Fuel Filter
12321 Black 10-micron Fuel Filter
12351 Chrome 10-micron Fuel Filter
12335 Red 40-micron Fuel Filter
12305 Fuel Filter Bracket| 12304 Red 100-micron Fuel Filter
12324 Black 100-Micron Fuel Filter
12354 Chrome-100 micron Fuel Filter
12331 Black-100 micron Fuel Filter w/ Shutoff Valve
---|---
Aero motive Electrical Components
16301 Standard Fuel Pump Wiring Kit
16307 Deluxe HD Fuel Pump Wiring Kit
16306 Fuel Pump Speed Controller
Aero motive system components are not legal for sale or use on emission-
controlled motor vehicles.
CAUTION:
Aero motive Phantom Components, including the Phantom 340 Stealth Pump and
the patented Foam and Bladder Baffle assembly, have been thoroughly tested for
use in common pump gas, non-oxygenated racing gas, ethanol including E85 from
corn, and petroleum based (not-bio) diesel fuel. Blending fuels and/or
additives, including cleaners, stabilizers or octane boosters, cannot be
tested and could result in damage to Phantom system components or other
components in the fuel system. These failures cannot be anticipated and may
not be covered under warranty. Contact the Aero motive Tech Department with
any questions on blending of fuels and/or use of additives.
** This Aero motive 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.
Note:** This fuel system is designed for Chevrolet Camaro/Pontiac Firebird
model years 1999-2002 with plastic fuel tanks only. Vehicles in the model year
1998 used a steel fuel tank, this system is not compatible with a steel fuel
tank.
The following steps are typical of most installations:
-
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.
-
Raise the vehicle on stable level ground and support it with jack stands.
-
Referring to the appropriate vehicle service manual for instructions, drain, disconnect any electrical and fuel system component connections and remove the OEM fuel tank. The removal of the vehicles exhaust system may be necessary for fuel tank removal.
-
With the new cleaned fuel tank on your preferred work surface, ensure you have all components listed above to complete the installation.
-
Using the lock ring removal tool, remove the OEM lock ring and carefully remove the OEM fuel pump assembly. Be careful to not damage the fuel level sender during the removal process as this can be reused later during assembly.
-
Remove the OEM fuel level sender from the OEM pump assembly. To do this, first unplug the connector from the bottom of the fuel pump outlet cap that has the two wires from the fuel level sender connected to it. Next, remove the small retainer clip from the fuel level sender, then press the two small tabs together while carefully pushing down on the level sender to remove it from the OEM pump assembly.
-
Cut the two wires from the fuel level sender loose from the plug, leave as much wire as possible. Then, strip the two wires and crimp on the two provided male spade terminals.
-
Next, install the fuel level sender on the provided fuel level sender bracket. To do this, slide the level sender upwards on the bracket while pressing the two tabs together and insert them through the slot on the top of the bracket. See the picture above for the proper fuel level sender orientation on the bracket.
-
Install the foam and basket assembly into the tank. To do this, first ensure the foam is pushed all the way into the black fuel basket before inserting into the tank. Next, roll the foam and basket and carefully insert into the tank, ensure the basket does not separate from the foam. Once in the tank, position the foam so it is concentric with the fuel pump hole in the tank. The window in the tank should be facing the passenger side of the tank.
Note: The orientation of the window in the foam is important as this is where the fuel level sender will pass through. See pictures below.
-
Next, loosely insert the fuel level sender bracket/fuel level sender through the window in the foam. Be careful not to bend or damage the fuel level sender while inserting it in the tank. Make sure to leave the sending unit wires sticking out of the hole to connect them to the wires attached to the outlet cap. See pictures below.
-
Once the fuel level sender bracket assembly has been loosely installed in the tank, install a new fuel pump assembly gasket (not included).
-
Connect the two white wires from the outlet cap (LVL and LVL) to the two wires from the fuel level sender and loosely insert the fuel pump assembly into the tank. Push the white wire excess through the window in the foam and loosely hang the fuel level sender bracket flange on the edge of the hole as shown in the picture below.
-
Before fully inserting the pump assembly into the tank you must connect the fuel level sender bracket to the outlet cap. To do this, pull up on the fuel level sender bracket and align the slots with the two 10-24 studs on the underside of the outlet cap. Attach the level sender bracket to the outlet cap using the two provided 10-24 Nylock nuts. A small 3/8” wrench works well for this step.
-
Fully install the pump assembly and fuel level sender into the tank. Caution: Take special care to ensure that the fuel pump wires, and fuel level sender wires are fully inside the tank and will not be pinched in between the pump assembly outlet cap and the fuel tank.
-
Rotate the pump assembly outlet cap so the orientation looks like the picture below. Note: This is very important as the fuel level sender will not read correctly if the cap is not oriented as shown in the picture below.
-
Ensure the gasket is seated in the groove and re-install the OEM fuel pump lock ring and tighten.
-
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 connections will not be accessible. For electrical wiring refer to Figure 2-1.
-
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. Additional fabrication may be necessary to gain clearance in extreme cases. Note: Tank vent must be at least 6” above the top of the tank if a roll-over valve is used highly recommended).
-
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 Aero motive part # 12345 for single pumps, or part # 12339 for dual pumps). 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.
Note: Above diagram shows typical plumbing of a Single
340, Dual 340, or Single 450 pump Stealth system. -
Connect electrical power (12 VDC) to the pump(s). 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.
Note: One 30 AMP relay required per pump. Connect the Aeromotive fuel pump(s) as shown in the following diagram:
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 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 ensure 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 ensure 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)!
WARNING: This product can expose you to chemicals, including chromium,
which is known to the State of California to cause cancer or birth defects or
other reproductive harm. For more information, visit:
www.p65Warnings.ca.gov
AEROMOTIVE, INC. LIMITED WARRANTY
This Aero motive Product, 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 Aero motive and not through any point of distribution
or purchase.
If a defect is suspected, the retail purchaser must contact Aero motive
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.
Aero motive 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. Aero motive will then, at it’s
sole discretion, return, repair or replace the product.
If any Aero motive product is determined defective, buyer’s exclusive remedy
is limited in value to the sale price of the good. In no event shall Aero
motive 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 without 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 Aero motive 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 Aero motive 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