| APSCC6-FSS/09 Installation Guide | ||
| 1 | Remove the stock differential and gearbox assembly in accordance with the Factory Service Manual. | |
| 2 | Remove the stock fuel tank assembly in accordance with the Factory Service Manual.
Hint: removal of the stock support bracket makes for easier removal of the stock crossover tube. |
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| 3 | Remove the stock fuel pump assembly from the fuel tank.
Hint: Unclip where shown. |
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| 4 | Cut the stock sender unit wires so that the sender unit can be removed and installed into the APS swirl pot/pump assembly. |  |
| 5 | To remove the stock sender unit assembly, first unclip the stock lower pump assembly. |  |
| 6 | Remove the stock sender unit by depressing the clip shown and sliding the sender unit upwards. |  |
| 7 | Install the stock sender unit into the APS swirl pot/fuel pump assembly and retain with an 8mm socket head screw (Item 39L) and 8mm washer (Item 39M). |  |
| 8 | Solder the wires shown to the sender unit wires and connect to corresponding terminal leads on the APS swirl pot/pump assembly (Item 39). |  |
| 9 | Carefully lower the swirl pot/pump assembly (Item 39) into the stock fuel tank ensuring that the RHS return hose is positioned in the centre of the fuel pumps. |  |
| 10 | Connect the RHS fuel supply hose as shown and lower the swirl pot/pump assembly (Item 39) fully into place in the stock fuel tank. |  |
| 11 | Insert a quick connect fitting (Item 21) and a 90 deg swivel fitting (Item 22) into the 15" fuel hose (Item 36). Install the protective spiral wrap (Item 37) over the hose assembly. |  |
| 12 | Install the fuel return hose assembly and fuel pump supply hoses (Items 24 & 25) as shown.
Connect the wiring loom connector (Item 38) as shown. Note: Ensure that the orientation of the hoses are as shown. |
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| 13 | Position the relay and wiring loom assembly (Item 38) as shown on the fuel tank. |  |
| 14 | Remove the stock fuel supply hose from the stock hard fuel supply line. This line will now be used as the new fuel return line.
Lift the fuel tank into the vehicle and route the fuel hoses above the chassis. Refit the new fuel supply hoses (Items 24 & 25) and the new fuel return hose assembly between the chassis rail and the floor as shown. |
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| 15 | Unclip the stock brake lines and lift the brake lines from the chassis rail.
Pass the fuel supply hoses (Items 24 & 25) between the chassis rail and the brake lines. Drill a 5/32" hole into the chassis rail for the hose support clamp (Item 30). Note: The fuel tank is behind the chassis rail so use caution when drilling. Retain the fuel supply hoses (Item 34 & 25) using the hose support clamp (Item 30) and a self tapping screw (Item 34). |
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| 16 | Secure the fuel supply lines (Item 24 & 25) using the support bracket (Item 29), hose support clamp (Item 30), bolt (Item 31), washer (Item 33) and nut (Item 32).
Use the additional hose support clamps (Item 30) and bracket (Item 29) as shown to further support the fuel supply hoses (Item 24 & 25). |
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| 17 | Route the fuel supply hoses (Items 24 & 25) above the stock clutch line along the LHS of the gearbox bell housing. |  |
| 18 | Connect the power and earth wires to the relay next to the fuel tank as shown. |  |
| 19 | If the MSD Booster Pump was previously installed, reconnect to the stock wiring at the plug.
Tuck the relay wiring up between the chassis rail and the fuel tank. Route the wiring with the fuel hoses towards the front over the bell housing to the RHS fuse box. |
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| Fuel Rails and Fuel Hoses | ||
| 20 | Remove the stock purge solenoid valve from its mounting bracket located at the front of the RHS cylinder head. Remove the stock purge valve solenoid mounting bracket. | |
| 21 | Drill a new mounting hole 1/2" (12.5 mm) from original 10.5 mm diameter mounting hole. |  |
| 22 | Mount the modified purge solenoid valve mounting bracket using the new mounting hole.
Install the purge solenoid valve onto the mounting bracket. |
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| 23 | Apply thread sealant to the LHS fuel pressure regulator fittings (Items 6, 10 & 12) and install into the LHS fuel pressure regulator housing (Item 7).
Apply rubber lubricant to the fuel pressure regulator (Item 8) and insert into the LHS fuel pressure regulator housing (Item 7) and retain with a circlip (Item 9). Note: The orientation of the components is important - mount as shown. |
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| 24 | Apply thread sealant to the RHS fuel pressure regulator fittings (Items 6, 10 & 11) and install into the RHS fuel pressure regulator housing (Item 7).
Apply rubber lubricant to the fuel pressure regulator (Item 8) and insert into the RHS fuel pressure regulator housing (Item 7) and retain with a circlip (Item 9). Note: The orientation of the components is important - mount as shown |
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| 25 | Install the fuel rail mounting brackets (Item 2) to each fuel rail (Item 1) and secure with 4mm x 20mm bolts (Item 3). |  |
| 26 | Install the short 9/16" JIC adaptor (Item 4) to the RHS fuel rail (Item 1) and the long 9/16" JIC adaptor to the LHS fuel rail (Item 1).
Install the banjo to each fuel rail (Item 7) adaptor (Item 14) with a 20/26mm copper washer (Item 15) at each side and retain with a banjo bolt. Note: Do not tighten the rear fittings as these will be tightened at a later stage. |
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| 27 | Locate and orientate the following components in preparation for installation onto the engine.
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| 28 | Apply rubber lubricant to the fuel injector O-rings and install the fuel injectors into the LHS and RHS fuel rails.
If using the ling Siemens fuel injectors included in the APSCC6-TTS/01 Twin Turbo System, install the fuel rail assemblies into the intake manifold and retain using the mounting spacer (Included in the APSCC6-TTS/01 Twin Turbo system) and bolts (Included in the APSCC6-TTS/01 Twin Turbo system). |
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| 29 | Install the fuel supply hoses to the rear of the fuel rails.
Mark the orientation of the fuel rail banjo fittings (Item 14) on each fuel rail. Remove the fuel rail assemblies. Tighten the rear fuel supply banjo fittings into the fuel rails. Reinstall the fuel rail assemblies as described above. |
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| 30 | Install the fuel supply hoses to the banjo fittings at the rear of the fuel rails and fully tighten.
Route the wiring over the drive tube and up the RHS of the firewall. |
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| 31 | Install the fuel pressure regulator assemblies to the fuel rails.
Install the stainless steel braided fuel pressure balance hose (Item 23) between the two fuel pressure regulators as shown. Install the 12" fuel return hose (Item 16) between both fuel pressure regulators as shown and retain with the fuel injection hose clamps (Item 20) at each end. Install the vacuum hoses (Item 28) between the two fuel pressure regulators and steel tee-piece (Item 27) as shown. If installing to a vehicle equipped with an APSCC6-TTS/01 Twin Turbo System, route a vacuum hose (Item 28) from the tee-piece between the two fuel pressure regulators (Item 27) and using the plastic tee-piece (Item 26), tee into the BOV hose under the RHS fuel rail as shown. If installing in applications other than the APSCC6-TTS/01 Twin Turbo System, connect the vacuum hose (Item 28) to a full manifold vacuum source. |
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| 32 | Install the return fuel hose (Item 18) from the LHS fuel pressure regulator to the stock steel fuel supply line.
The stock steel fuel supply line now acts as the new fuel return line back to the fuel tank. |
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| 33 | If installing to a vehicle equipped with the APSCC6-TTS/01 Twin Turbo System connect the fuel pump power wire to the power supply previously connected to the MSD Booster Pump.
If installing in an application other than with the APSCC6-TTS/01 Twin Turbo System, connect to a reliable, fused full 12 V power source. |
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| 34 | Switch the ignition on and off several times to pressurize the fuel system.
Check all fuel connections closely for any signs of fuel leakage. |
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