ProFlow PFEST9BK User manual

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INSTALLATION MANUAL
Ford Falcon BA/BF/FG Undercar Surge Tank
PFEST9BK
Included Items
QTY
PFEST9BK Surge Tank 2.0L
1
M8 x 40mm Hexagon Flange Bolts + Washers ISO 4162
2
M6 x 12mm Socket Head Cap Screw ISO 4762
4
WARNING: PLEASE READ ALL INSTRUCTIONS BEFORE PROCEEDING. PROFLOW WILL NOT BE
RESPONSIBLE FOR ANY DAMAGE AS A RESULT OF THE INCORRECT INSTALLATION OF THIS
PRODUCT. IT IS RECOMMENDED THAT A QUALIFIED AUTOMOTIVE TECHNICIAN PERFORMS THIS
INSTALLATION.
WARNING: THE INSTALLATION OF THIS PRODUCT REQUIRES THE HANDLING OF FUEL. IT IS
RECOMMENDED TO WORK IN A WELL-VENTILATED AREA AND WEAR APPROPRIATE PERSONAL
PROTECTION. KEEP ALL IGNITION SOURCES AND FLAMES AWAY FROM THE VEHICLE AT ALL TIMES.

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Fuel Pump Plumbing
Single Pump
1. Bolt the single fuel pump bracket (PFEBOSBKBLK purchased separately) to the
surge tank with M6 screws using the two threaded holes.
2. Insert your 044 style fuel pump into the bracket with the supplied rubber sleeve.
3. Using barbed fittings, 1/2" rubber hose and clamps, plumb the right-hand side port
on the bottom of the surge tank to the fuel pump as shown in figure 1 below. All
fittings and hose can be purchased separately.
Figure 1
4. Block the second pump supply port with the appropriate ORB plug fitting as this
port will not be used.
5. Ensure all fittings are securely fastened and all hose is secured with clamps.
Dual Pumps
1. Bolt the dual fuel pump bracket (PFEFS5076BK purchased separately) to the surge
tank using the supplied M6 screws and the two countersunk bolt holes located on
the back of the base plate.
2. Insert your 044 style fuel pumps into the dual bracket with the supplied rubber
sleeves. Tighten the pump clamp.
3. Using barbed fittings, 1/2" rubber hose and clamps, plumb both pump supply ports
to the fuel pumps as shown below in figure 2 (most convenient plumbing solution
shown). Please note that the pumps may need to be pushed slightly away from the
tank to make space for the barbed fittings for the inner fuel pump.

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Figure 2
Note: This dual pump setup uses a 90 degree push-lock fitting with an AN8 straight
fitting to plumb the inner fuel pump.
4. Ensure all connections are securely fastened and all hose clamps are tightened.
Surge Tank Installation
1. Disconnect the battery from the vehicle
2. Jack the front of the car off the ground and ensure suitable stands are used with
the vehicle in park and with the handbrake on. Ensure both sides of the vehicle are
jacked correctly.
3. Remove the two bolts on the front left hand side sway bar bracket.
Note: Starter motor wiring may need to be re-routed to provide adequate clearance
for the surge tank.
4. Disconnect both fuel lines where the flexible hose meets the hard-line piping along
the left-hand side of the vehicle. These are OEM style connectors, and the tabs
need to be pushed together to release.
5. It may now be best to screw AN6 fittings into the return, supply and overflow ports
on the surge tank before placing it on the vehicle.
6. Using the supplied bolts and washers, bolt the surge tank in place using the sway
bar bracket bolt holes.
7. Connect the pump(s) outlet hose(s) to the fuel rail feed line which will supply the
vehicle with the high-pressure fuel to the fuel rail.

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8. Connect the OEM or lift pump from the main fuel tank to the middle port labelled
‘tank supply’ on top of the surge tank using the appropriate quick connect hose and
fittings. This will supply the surge tank with fuel from the main fuel tank.
9. Connect the fuel rail return hose (which may come from the regulator depending
on setup) to the lower AN6 port on the surge tank.
10.Plumb the top port labelled ‘tank return’ back to the main fuel tank hard line which
will feed the main fuel cell when the surge tank is full (while idling for example).
11.Ensure all fittings and connections are securely tightened before proceeding.
12.Wire the fuel pumps using the appropriate high amperage wiring, fuses, and relays.
13.Before starting the car, the surge tank will need to be primed with fuel. This can be
done by cycling the vehicle’s ignition power on and off several times. This will
activate the primary lift pump in the main fuel tank to fill the surge tank.
14.Start the vehicle and finally inspect the surge tank assembly for any leaks.
Surge Tank Plumbing Diagram
The below diagram shows an example of plumbing the surge tank when using a single
fuel pump:
Note: This surge tank must always be mounted in the orientation shown above if mounting
elsewhere on the vehicle or using it universally (vertically).
PROFLOW LIMITED WARRANTY
This product is warranted to be free from defects in materials and
workmanship for a period of one year from the original date of purchase.
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