Plumbing: The fuel supply pick up tube, fuel lines, and fittings shall be no smaller than
½” inside diameter between the fuel tank and Aero Motive high-pressure fuel pump. The
fuel pump must also have the supplied serviceable 100 Micron filter installed on the inlet
side of the fuel pump.
When using an auxiliary engine such as an outboard motor, never plumb or tee into the
main engine fuel system. The auxiliary engine shall have its own fuel pick up tube and
fuel filter/water separator from the fuel tank. Plumbing into the main engine fuel supply
will cause damage to the engine and fuel pump system.
Fuel pump placement: The Aero Motive fuel pump must be placed as close to the fuel
tank as possible. A 30” Maximum distance from the fuel tank outlet to the fuel pump
inlet shall not be exceeded.
The fuel pump must also be placed as low to the bottom of the fuel tank as possible.
Using the lowest point on the bottom of the fuel tank, mount the fuel pump at a
Maximum vertical distance of 12” from the bottom of the fuel tank. Check for any laws
and/or restrictions that may apply.
The Racor fuel /water separator should NEVER be placed on the outlet side of the high-
pressure fuel pump. The fuel filter/water separator shall also be mounted within a
Maximum distance of 12” vertical from the bottom of the fuel tank.
Hoses: Use only USCG Approved fuel lines. Check for any laws and/or restrictions that
may apply. Check when routing the fuel lines that they are not laying over, or rubbing
against any sharp edges.
Fittings: When choosing fittings, the use of a 90°full flow design is preferable over the
restricted tight 90°fittings.
Setting the fuel pressure: After all the fuel plumbing is complete, set the Initial fuel
pressure by cycling the ignition switch (key on/engine off) and adjust the setscrew on
the regulator until you are in the 65-psi range. This may take a few cycles of the key
switch for the fuel to fill the fuel lines, filter, and fuel rail. Check to make sure there are
no fuel leaks at all of the connections, tighten as necessary.
Once the vessel is in the water with the engine running at idle, you can now fine-tune the
fuel pressure to the target 65-psi Minimum, 67-psi Maximum pressure. After the fuel
pressure has been set, tighten the lock nut down on the fuel pressure regulator, and
double check for any fuel leaks in the fuel system.
Once the fuel pressure has been confirmed under a sea trials situation and the fuel
pressure is within the Minimum/Maximum setting described above, tamper proof the fuel
regulator adjustment screw. Tamper proof by using a small amount of tamper proof
compound, or an oil-based paint marker on the setscrew, locknut, and body of the
regulator.
