This installation is for an inline pump with a check valve. The relay used with this installation was pre-wired. However, a diagram has been attached to these instructions for ones that are not pre-wired.
1. Locate the place where the fuel pump is to be installed, on the driver’s side frame rail, about 5-6 inches after the bend in the fuel line. You can drain the line by removing outflow line at the fuel filter using a fuel line separator, which can be purchased any parts store. I was able to drain it into a glass jar, which helped to minimize the mess. I also had the injectors removed so there wasn’t any vacuum to keep the fuel from draining. Relieving the pressure at the rail, where the Schrader valve is, would do the same.
2. Remove the fuel lines and brake line from the clamps that hold them to the frame rail and on the metal bracket where they bend and go up to the engine. This will allow more room to cut the fuel line and install the pump.
3. Place the fuel pump with the brackets on the frame rail above the oval slot and mark the holes with a punch or scribe and drill the holes. I would recommend not mounting the pump at this time.
4. Cut the fuel feed line (the one coming from the fuel filter) with a tubing cutter and keep the newly cut area away from any dirt or debris.
5. Mount the fuel pump at this time with the electrical terminals facing the back of the truck and mount the Black 8 inch ground wire to one of the mounting screws on the pump bracket, and the other end to the “Negative” terminal on the pump. Notice the “Flow” arrow on the pump to get an idea of the direction of fuel flow. Once the pump is installed, bend (but do not kink or crease) the hoses and slide the metal fuel lines all the way into the compression fittings and tighten. When it’s complete it should look close to this (Figure 1).
Figure 1
6. Attach the Red wire to the “positive” terminal of the fuel pump and route it up to the engine on the driver’s side, remove this wire from the relay if it is attached to make the install a little easier. You can use the plastic conduit that the factory has installed to hide the wire. Carefully cut away the places that are taped, insert the wire, and then fasten with some wire ties. Feed the wire so that it comes out near the distribution box on the driver’s side fender well. Ensure that the wire is free from being nicked or cut, you can use plastic automotive conduit to protect the wire from damage.
7. Locate the mounting hole for the relay, just under the hood recoil spring and slightly behind the Cruise Control (Figure 2). There is a threaded hole that is already there, you can mount the relay there by using a #12 screw (double check the size to ensure proper fit). Do not tighten the relay at this time. Attach the red wire from the pump back to the relay (Pin #87), and tighten the relay down. Ensure that the wires wont rub on anything. Secure all lose wires with some wire ties.
Figure 2
8. If you’re using an FMU, cut the vacuum line roughly 3 inches from the fitting and insert the “T”. Then, insert one end of the supplied 5/32 vacuum line into the “T” and the other to the Hobbs switch (Figure 3), and mount the Hobbs near the FMU
Figure 3
9. Connect the Red wire (with the fuse holder) to the power lug on the distribution box. Just slide the cover straight up to remove it (Figure 4).
Figure 4
10. Ensure that the relay is wired properly (Figure 5)
Figure 5
