Aero-motive A1000 User manual

AEROMOTIVE
Part # 11101, 11108 & 11151
A1000 Fuel Pump
INSTALLATION INSTRUCTIONS
This product is not legal for sale or use on emission-controlled vehicles except when used as a direct
replacement part matching OEM specification.
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/ the fuel
system, failure to satisfy all safety considerations will result in fire, explosion,
injury and/or loss of life to yourself and/or others. All fuel system components
MUST be located as far from heat sources as possible, like exhaust, engine block,
etc.
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 other
appropriate 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
damge to the product, injury or loss of life to yourself and/or others.

Compatible Fuels:
Pump Gas
Race Gas
E85
Alcohol/Ethanol
To use this pump in your vehicle’s fuel system, you must do the following:
A by-pass style fuel pressure regulator must be used in the system.
Utilize AN-10 size high pressure fuel lines, fittings and o-rings for all connections from the fuel
tank pickup to the fuel pump.
To ensure proper fuel pump performance and longevity, mount pump level with or lower than
the bottom, and as close to the tank, as possible.
Install a 12304 pre-filter and 12301 post filter.
If you are using a stock fuel tank, install a reservoir sump in the bottom-rear of your fuel tank.
Exercise extreme caution and follow all manufacturers’ recommendations when installing a
reservoir sump. (Sump part # 18650)
Tank/Fuel cell must have at least a ½” tank vent.
If you choose not to install a reservoir sump, then you must install a high flow capacity fuel tank
pickup (9/16” to 5/8” inner tube diameter). Installing pickup tube instead of a reservoir sump
may shorten the fuel pump life and cause drivability problems. When using a pickup, you
should maintain at least ½ tank of fuel to avoid possible engine lean-out and/or fuel pump
damage.
For long term driving applications where continuous run times exceed 30 minutes and fuel
capacity is less then 10 gallons, Aeromotive recommends the installation of a Fuel Pump Speed
Controller to maintain lower fuel temperatures in the tank. See Aeromotive Fuel Pump Speed
Controller 16306.
Maximum continuous operating pressure should not exceed 70 psi.
Failure to follow the above 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!
The enclosed Aeromotive fuel pump utilizes AN-10 ORB (O-ring Boss Ports) style inlet and outlet ports; these ports are
NOT PIPE THREAD and utilize NO THREAD SEALANT.

The following steps are typical of most installations:
1. Referring to the appropriate vehicle service manual for instructions, remove the OEM fuel pump.
2. Install an after-market sumped high flow capacity fuel tank or fuel cell, per the manufacturer’s instructions.
3. Find a suitable place on the vehicle chassis to mount the fuel pump. Make sure the location will accommodate the
pump mounting bolts. Make sure to position the pump at or below the bottom of the tank. Make sure that the pump is
clear of the exhaust, is clear of any moving suspension or drivetrain components and will keep the pump clear of road
obstructions or debris.
4. Using the enclosed template, mark and drill four mounting holes to accept ¼” bolts. Mount the fuel pump using four ¼”
bolts, nuts and lock washers. For quieter fuel pump operation use Aeromotive p/n 11601 fuel pump vibration
dampening mounting kit.
Note: Be sure to route all fuel lines clear of any moving suspension or drive train components, and any exhaust
components! Protect fuel lines from abrasion and road obstructions or debris.
5. Using minimum of 9/16” ID or AN-10 fuel line, connect the fuel tank sump outlet to a 12304 fuel filter. Using the same
size fuel line connect the fuel filter outlet to the fuel pump inlet, or if you are using an Aeromotive fuel filter you can
attached the filter directly to the fuel pump utilizing an AN-10 fitting (15608) and 2 sealing o-rings (10AN o-ring pack
15623).
Note: It is recommended that a fuel shut off valve be installed between the fuel tank outlet and the fuel pump.
Use Aeromotive part # 12331 shutoff valve fuel filter and 15640 swivel fitting to make the connection.
6. Using AN-10 fuel line, connect the fuel pump outlet to the 12301 fuel filter. You can attached the filter directly to the
fuel pump utilizing an AN-10 fitting (15608) and 2 sealing o-rings (10AN o-ring pack 15623). Make sure you use high
pressure (150 psi minimum) fuel line for this connection!
7. Using AN-08 or AN-10 fuel line, connect the fuel filter outlet to the “Y” block (15620, 15674 or 15675). From the “Y”
block use AN-08 lines to make the connection to the fuel rails. Make sure you use high pressure (150 psi
minimum) fuel line for this connection! For optimum fuel system performance in EFI applications, Aeromotive
recommends a balanced system with the fuel pressure regulator as the last component in the system as shown in the
following diagram.

Note: Be sure to route all electrical wires clear of any moving suspension or drivetrain components and any
exhaust components! Protect wires from abrasion and road obstructions or debris.
8. Make sure you use stranded, insulated copper wire, in the sizes shown, with matching crimp-type connectors for all
connections.
9. Locate the OEM fuel pump supply wires, located near the OEM fuel pump mounting location. Using that supply wire,
connect the Aeromotive fuel pump as shown in the following diagram.

10. Attach a suitable, non-liquid filled fuel pressure gauge, or one of the new Aeromotive liquid filled gauges with
equalizer valve to the fuel system schrader valve, fuel rail or fuel pressure regulator.
P/N 15632 0-15 PSI (1 ½”) “Liquid Filled” Fuel Pressure Gauge with equalizer valve.
P/N 15633 0-100 PSI (1 ½”) “Liquid Filled” Fuel Pressure Gauge with equalizer valve.
Ensure that any spilled fuel and any fuel soaked shop towels are cleaned up and removed from the vicinity of
the vehicle.
CAUTION: While performing the following steps, if any fuel leaks are detected, immediately turn the ignition to
OFF, remove any spilled fuel and repair the leak(s) before proceeding!
11. Turn the ignition to 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 ignition to OFF, wait one minute, then turn the ignition to ON and recheck
the pressure. Repeat this ignition OFF and ON procedure until the gauge registers pressure or you detect a fuel leak.
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.
12. Once the fuel pressure gauge registers pressure, start the engine. The fuel pressure gauge should register between
40 and 70 psi. If you have installed an adjustable fuel pressure regulator, adjust it to the desired setting. (For
maximum fuel system performance, we recommend using an Aeromotive adjustable fuel pressure regulator; call us
for info.)
13. Shut the engine off. Using suitable clips and other mounting hardware, secure the newly installed fuel lines and
electrical wires by attaching them to the vehicle chassis.
14. Test-drive the vehicle to insure 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)

Fuel System Troubleshooting
Pump does not run at all.
Do you have voltage at the
pump terminals?
Is the “+”terminal
connected to +12 V and the
“-“ terminal connected to
the battery
ground
cable
?
Is the fuel line going to the
engine compartment
connected to the same side
of the fuel pump as the
power terminals?
Do you have a 100-micron
fuel filter installed on the
inlet side of the fuel pump?
Contact Aeromotive
Check all
electrical
connections.
Connect power
wires to proper
terminals.
Plumb the fuel
pump in the
proper orientation.
Debris may have
entered the fuel
pump and locked
it up, Contact
Aeromotive.
Yes
Yes
Yes
Yes
No
No
No
No
Pump performs poorly or runs intermittently
Is the fuel pressure
regulator you are
using a by-pass
style
?
Are you using a
sumped fuel tank or
a fuel cell?
A by-pass style regulator is
required for proper operation of
this product. For EFI we
recommend Aeromotive p/n
13101 or 13109. For carb
applications we recommend
Aeromotive p/n 13204.
A sumped fuel tank or fuel cell
is required for proper product
performance, refer to
Aeromotive tech bulletin #802
“Pickup tubes -vs- sumped
tanks” for specific details.
Is the fuel line
between the fuel
tank / fuel cell a
minimum of 9/16”
ID or AN-10?
Is the fuel pump
mounted at or below
the half tank fuel
level?
Does the fuel filter
on the inlet side of
the pump have a
100-micron
filtration rating and
have a min. of 60 in
2
area?
Are the fuel filters
in the system been
clean or new?
Clean, high flow inlet plumbing
is required for proper pump
operation, a min. of 9/16” ID or
AN-10 fuel line is required on
the pump inlet side.
Are you driving the
vehicle for periods
of time greater then
30 minute with less
the 10 gallons of
fuel in the tank?
Contact Aeromotive
As the fuel level falls in your
tank it is being recirculated at
an increasing rate, allowing less
time for fuel cool down, in
these cases it is recommended
to use a Fuel Pump Speed
Controller, we recommend
Aeromotive p/n 16306
.
The fuel pump must be
mounted such that it has a good
gravity feed to insure proper
priming
a
nd a long service
life.
The fuel filter on the inlet side
of the fuel pump is required to
be rated at 100-micron and
have no less then 60 in
2
filtering area. For detailed
information see Aeromotive
tech bulletin #101 titled “Inlet
Filtra
tion
”.
Insure that all fuel filters are
clean or new, proper filters are
an inexpensive cure to a lot of
fuel system problems. Refer to
Aeromotive tech bulletin #102
titled “Post Pump Filtration”.
Yes
No
Yes
Yes
Yes
Yes
Yes
Yes
No
No
N
o
No
No
No

Aeromotive,Inc. TechnicalBulletin #101
From: Aeromotive Technical Department
Date: 10/10/2011
Re: Fuel Filtration: Selecting the correct filter to prevent lean-out and pump failure.
STOP!! If you are selling or installing a fuel filter on the inlet of an Aeromotive fuel pump, be certain
you do not use a filter that causes more problems than it solves. For pump inlet filtration, use only
Aeromotive 100-micron P/N #12304, #12302 or an acceptable equivalent (see specifications below).
Do not install the Aeromotive P/N #12301 or 12310 filter with 10-micron fabric element on the inlet of
any Aeromotive fuel pump, they are however perfect for use on the outlet of the pump, and this is the
only location for which they are recommended.
You may run any brand of filter you choose on your car, just be certain that it meets the following requirements:
The filter element used on the inlet side of any Aeromotive fuel pump may be no finer than 100-micron (no
number smaller than 100), with a surface area of 60 square inches or more.
Any filter element not meeting these criteria may fail to flow the full volume of the pump, resulting in both
vehicle drivability and pump reliability problems. Aeromotive fuel pumps are engineered to be efficient, and
can create both high outlet pressure and high inlet vacuum. The boiling temperature of any liquid varies with
pressure. For example, the engine’ cooling system is purposely designed to pressurize the coolant in order to

raise the boiling point. So how does this apply to fuel delivery? When a fuel pump has to pull through a
restriction to get fuel from the tank a vacuum develops which lowers the fuel’s boiling temperature, cavitating
the fuel and turning it from liquid into vapor. Bottom line: Inlet restrictions create vacuum, which causes
cavitation, which in turn causes vapor-lock and fuel pump damage. Of course, drivability problems and even
engine damage can result! Lesson: Don’t combine high flow, efficient fuel pumps with poor flowing inlet
filters. Don’t use fuel lines smaller than the pump ports. Don’t use fuel tank pick-ups or tank outlets smaller
than the line.
What about a fine filter? They are also necessary, but must be installed on the outlet side of your Aeromotive
fuel pump, never on the inlet. Options include the Aeromotive 10-micron (replaceable element) fabric filter
assemblies P/N #12301 and P/N #12310, and the new, high-flow 40-micron (cleanable element) stainless steel
filter assembly P/N #12335. Given the alcohol content found in today’s pump gas, it is now necessary to
frequently monitor and service any downstream fuel filters in use. Because they cannot be cleaned, keep a spare
10-micron element on hand for immediate service to eliminate engine fuel starvation and drivability problems
when they become heavy clogged.
All Aeromotive pumps except the Pro Series EFI pump may use the Aeromotive filter #12304 with –10
inlet and outlet fittings and 100-micron stainless steel element. The Pro Series EFI pump #11102 requires
filter #12302 with larger stainless steel element and –12 inlet and outlet fittings. The #12302 is also
recommended for the #11104 EFI Eliminator pump and our new #11105 belt drive pump (try 400gph or
2700lb/hr of fuel delivery at 100psi!!). Though Genuine Aeromotive Filters may be somewhat more
expensive than the off-brand options, you simply must “compare apples to apples”. They say “a picture is
worth a thousand words…”

Above are various versions of “100-micron” fuel filters/elements. Note: the top element is the Aeromotive 100-
micron element P/N #12604, as found the fuel filter assembly P/N #12304. Note the various filters all have
“billet” housing, with AN connections, and can be disassembled for inspection and cleaning. Also, note that all
are sold and recommended as appropriate pre-filters.
Of course, it’s obvious by this comparison image that there’s more to a filter than the micron rating, a billet
housing or even AN Connections. It should be equally clear that surface area, the amount of filter material
available for fuel flow, is not at all related to micron rating, but a major key to a filters flow capacity. All these
filters may be fine, well made assemblies, and perhaps they are suitable for use with various fuel pumps on
various engines; However, excepting the very top element which is there for comparison, none of the above
belong in any system featuring an Aeromotive fuel pump and certainly not any car, boat, truck, etc. that
features an engine worthy of such a pump.

Contact Us
RGA NUMBER REQUIRED FOR ALL RETURNS TO AEROMOTIVE.
To obtain an RGA number, please call (913) 647–7300 and ask for the Returns and Repairs department or
complete the online form under the “Rebuilds” section at www.aeromotiveinc.com .
Shipping & Returns
Aeromotive Inc.
11414 W 79th Street.
Lenexa, KS 66214
General Inquiries and Tech Line: [phone]
General Email: [e-mail]
Tech Email: t[email protected]
The Aeromotive Tech Lines are open Monday through Friday from 9:30AM to 5:00PM Central Standard Time.

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. 7805 Barton Street, Lenexa, KS 66214 Phone: [phone] Fax: [phone]
AEROMOTIVE, INC. LIMITED WARRANTY
This Aeromotive 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
Aeromotive and not through any point of distribution or purchase.
If a defect is suspected, the retail purchaser must contact Aeromotive 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.
Aeromotive 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. Aeromotive
will then, at it’s sole discretion, return, repair or replace the product.
If any Aeromotive product is determined defective, buyer’s exclusive remedy is limited in value to the
sale price of the good. In no event shall Aeromotive 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 Aeromotive
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 Aeromotive 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.