| APSGTO-FSS/05 GTO TWIN FUEL RAIL FUEL SUPPLY SYSTEM | ||
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1 |
Remove the fuel tank as per the factory manual instructions. | |
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2 |
Remove the APS pump assembly (supplied in APS GTO - FSS/06) from the fuel tank, if already installed. | |
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3 |
NOTE: To allow rotation of the 90° adaptors, remove the stock pressure sensor, wiring socket bulkhead screws and lift upwards. | |
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4 |
Remove the 90° adaptors, as shown, (supplied in APSGTO-FSS/06) |  |
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5 |
Using sealant, reinstall 90° adaptors and orient as shown.
Using new viton O rings (Item 25) reinstall the wiring bulkhead retaining bolts and nuts. |
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6 |
Reinstall APS pump assembly into the fuel tank. Reconnect wiring and the breather tube. |  |
| 7 | Connect the fuel supply hoses (Item 11) to 90° adaptors on the APS fuel pump assembly. Secure with ties (Item 26). |  |
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8 |
Remove tabs from the stock lower plastic tank cover. |  |
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9 |
Reposition the stock fuel tank in the modified lower plastic tank cover, noting the new fuel hose routing (Item 11). |  |
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10 |
Modify the top tank cover as shown by drilling a 3" hole. |  |
| 11 | Place the modified top plastic tank cover over the fuel tank and lower tray. Secure. |  |
| 12 | Reinstall the fuel tank into the vehicle. Route the fuel hoses (Item 11) through the hole in the floor pan. |  |
| 13 | Remount the APS wiring relay. |  |
| 14 | Reposition and secure the fuel filler sleeve using ties (Item 9). |  |
| 15 | Mount fuel rail brackets LS1 (Item 2A) or LS2 (Item 2B) to fuel rails (Item 1) using M4 x 0.7 x 20mm bolts (Item 3). |  |
| 16 | Install adaptors (Item 4) to the RHS fuel rail (Item 1). |  |
| 17 | Install adaptor (Item 4) to the rear end of the LHS fuel rail (Item1).
Install adaptor (Item 5) using an O ring (Item 20) to the front end of the LHS fuel rail. At the same end (as shown) screw in the Tee fitting (Item 6) using sealant. (Note the orientation of the Tee fitting (Item 6)). |
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| 18 | Install fuel rails (Item 1) and whichever injectors you choose to use. NOTE: LS2 requires non standard O-Rings on the manifold side of injector. Unlike most injector mountings which are machined for 14.5mm O.D. O-Rings; the LS2 is machined for 15.5mm O.D. O-Rings. Ensure that the correct dimension O-Ring is used. |  |
| 19 | Using a 7/8" Hole saw make an opening in the rear of the RHS chassis rail as shown. |  |
| 20 | Feed RHS (Item 12) and LHS (Item 13) fuel hoses through the hole in the RHS chassis rail. |  |
| 21 | Remove the stock RHS rear heat shield (positioned forward of the rear sub frame). | |
| 22 | Route the fuel hoses (Items 12 &13) rearward along the chassis rail and above the rear sub frame to the fuel tank hoses (Item 11). NOTE: Do not secure hoses to chassis yet. | |
| 23 | Connect the fuel hose joiners (Item 8) to the fuel tank hoses (Item 11). |  |
| 24 | Connect the front fuel hose (Item 12 & 13) to the joiners (Item 8) . Secure them to the stock fuel line using a tie strap (Item 9).
Ensure there is adequate clearance from the rear sway bar. Modify the stock rear heat shield as shown. |
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| 25 | Apply spiral wrap (Item 21) to fuel hoses where they pass through the hole in the RHS chassis rail, as shown. |  |
| 26 | Route the fuel hoses (Item 12 & 13) up through rear of the engine bay and connect to the rear end of the fuel rails (Item 1). |  |
| 27 | Carefully modify the stock LHS front engine lifting hook by bending it forward. |  |
| 28 | Remove the Y adaptor from the fuel pressure regulator.
Remove the side fuel straight adaptor. |
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| 29 | Install the side adaptor and plug (Item 19) using an O ring (Item 27) as shown.
Install new regualtor bracket (Item 7) to the regulator. |
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| 30 | Fit the regulator with bracket to the bracket supporting clutch fluid reservoir.
NOTE: Right hand drive vehicle shown; however the same mounting arrangement used in LHD vehicles. |
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| 31 | Install push lock fittings (Item 17 & 18) to the fuel injection hose (Item 16), retaining the Quick Connect hose fitting (Item 17) with a Hose Clamp (Item 27). |  |
| 32 | Connect the balance hose (Item 14) between the fuel rails (Item 1) at the front of the engine. | |
| 33 | Connect the fuel hose (Item 15) from the LHS fuel rail to the regulator side adaptor.
Connect the fuel return hose (Item 16) from the regulator to the stock fuel supply line (now used as a fuel return hose). |
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| 34 | Connect the pressure reference hose (Item 23) with Tee piece (Item 22) between the regulator and the BOV hose. |  |
| 35 | Turn the ignition on and off to bring up the fuel pressure. | |
| 36 | Check for fuel leaks. | |
