|KENNE BELL| —_ Hi Tech Performance Products BOOST-A-PUMP™ WIRING INSTRUCTIONS Installation of the KENNE BELL BOOST-A-PUMP™ (BAP) is simple and straightforward. All you need to do Is locate the "HOT" (12 VOLT POSITIVE +) wire going to your pump and wire the BAP 5 as shown in the following diagrams. NOTE: The INPUT wire to the BAP is the fused red wire, IMPORTANT! ON VEHICLES USING FEEDBACK TO THE ENGINE COMPUTER TO TELL IT WHEN THE PUMPS RUNNING - WIRE THE BAP AFTER THE FEEDBACK WIRE OR THE CHECK ENGINE LIGHT MAY COME ON. WIRE THE BAP ONLY AS SHOVIN IN THE FOLLOWING DIAGRAMS OR DAMAGE MAY OCCUR AND WARRANTY WILL BE VOID. fpouruerouwe 4. __ nomen RELAY OR OTHER — Fo Ss (aimee, @) Locare Posirive WIRE GoING To PUMP gener, = + STEP 1 FROM FUEL PUMP —Posmve wee RELAY OR OTHER PUMP SUPPLY (manual switch, pressure switch, ete.) @® 6UuT Positive WIRE GOING To PUMP FROM FUEL PUMP RELAY OR OTHER PUMP SUPPLY ‘TO GROUND (manual switch, Droscure switeh, etc.) RUN CABLE 10 INSDE OF CAR AND MOUNT ‘CONTROLLER TO INTAKE (vacuum switch) or SUPERCHARGER ‘or TURBO ouTer MANIFOLD (pressure / boost aa OR SWITCH AND CONNECT IT TO THE FUSED RED WIRE OF BAP. TAKE THE OTHER END OF THE WIRE THAT YOU CUT GOING ‘ON TO THE PUMP AND CONNECT IT TO THE OTHER RED WIRE. CONNECT BLACK WIRES. TO GOOD GROUND. YOUR PUMP WIRE NOW Cees "GOES THROUGH (IN AND OUT OF)" THE ANTI BOOST-A-PUMP. RUN CABLE FOR SWITCH per eth AND CONTROLLER AS SHOWN,Cotes eae PART# KB89066 / KB89067 20AMP KB&89068 / KB89069 40AMP BOOST-A-PUMP™ INSTALLATION INSTRUCTIONS 1, The Kenne Bell BOOST-A-PUMP" (BAP) may be mounted anywhere as long as itis protected from exposure to water or extreme heat (above 300” F). Preferred mounting is under the seat or in the trunk. 2. Locate the 12 volt + wire going to the fuel pump from the fuel pump relay. It is important that you positively determine the proper wire to splice into or the BAP will not function. Ifyou do not see your vehicle listed on our FUEL PUMP WIRE GUIDE, use your service manual or contact the dealer to determine the wire color and location. NOTE: ON VEHICLES WITH COMPUTER CONTROL, THE BAP SHOULD BE WIRED IN AFTER THE FEEDBACK TO THE COMPUTER, NOT BEFORE. A CODE MAY BE SET IF THE COMPUTER SEES HIGHER THAN NORMAL VOLTAGE TO THE FUEL PUMP 3. After you have located the fuel pump wire, trial fit the assembly first to insure the cables will reach their proper installation points. 4. The Cockpit Controller must be located inside the vehicle to allow access to the adjustment knob. The cable has a plug-in connector that can be routed through a small hole in the firewall or trunk depending on where the BAP module is mounted. Make sure that the cable will reach the module as this cable CAN NOT be extended. Extending this cable will affect the operation of the BAP 5. The other cable included in the kit goes from the BAP module to the activation switch (VACUUM for normally aspirated and BOOST for supercharged / turbocharged applications). Route this cable through the firewall or trunk from the switch location to the module. Make sure that the cable will reach the module because this cable CAN NOT be extended. Extending cable will affect operation of the BAP 6. If the cable(s) will not reach the desired location of the BAP module, the main #10 AWG POWER WIRES may be ‘extended up to ten (10) feet. Again, DO NOT EXTEND THE MULTI-CONDUCTOR CABLES, ONLY THE RED ‘AND/OR BLACK POWER WIRES may be extended. Use only #10 AWG copper stranded wire to extend the BAP power wires. Make sure all connections are solid and free from exposure to moisture. 7. Check to make sure you have the correct activation switch for your application. The VACUUM switch application has ‘two wires: RED and BLACK (RED from switch connects to the RED wire/ BLACK to BLACK). The SUPERCHARGED 1 TURBOCHARGED switch also has two wires: RED and BLACK. These simply connect to the BOOST switch. Polarity has no effect. 8, Install the VACUUM switch with a short piece (no longer than 24°) of 5/32" vacuum line from a good intake manifold vacuum source. ON SUPERCHARGED / TURBOCHARGED applications, install the BOOST switch with a short piece (no longer than 24") of 5/32" vacuum line to the BLOWER SIDE ONLY of the intake manifold (the BAP will not function ifthe line is on the inlet side of the supercharger / turbocharger). ‘9, Connect the fuel pump wires as shown in STEPS | - 3. The two BLACK ground wires on the BAP module may be connected to the frame if desired. IMPORTANT: THIS MUST BE A GOOD CLEAN GROUND CONNECTION FREE OF PAINT, RUST OR OTHER MATERIAL - DAMAGE TO THE UNIT CAN RESULT IF NOT ‘GROUNDED PROPERLY. (we recommend grounding the BLACK BAP wires to the battery NEGATIVE terminal or to the ground wire going to the fuel pump). 10. Mount the BAP module with the four (4) included self tapping screws. The module does not need to be mounted to : metal surface since the two black wires act as a ground, = |. Plug in the Cockpit Controller and activation switch cables. The BAP is now ready for use.PAGE 3 0f5 BOOST-A-PUMP™ FUEL PUMP WIRE GUIDE VEHICLE YEAR WIRE COLOR LOCATION Mustang 5.0L '86-'90 PINK w/ BLACK STRIPE Under driver's seat at relay Mustang 5.0L ‘91 -'938 GREEN w/ YELLOW STRIPE Under mass air meter Mustang 5.0L/4.6. ‘94 -'98 BROWN w/ PINK STRIPE In trunk in harmess Ford Trucks be GREEN w/ YELLOW STRIPE Under power distribution box under hood Buick GN '84-'87 TAN w/ WHITE STRIPE In trunk (left side )+++ Syclone/Typh '91-'92 GRAY Past bulkhead connector towards pump (see diagram). Fuel pump relay is located on the left side firewall. There are 2 relays; one for the A/C and the other for the fuel pump (closest to engine).+++ ‘Includes Cobra NOTE: DO NOT TIE INTO WIRE * All models and years from'‘91 up that we know of. AAT RELAY - VOLTAGE WILL FEED +++ You must change the stock fuel pump fuse from 10 AMP to 20 AMP. BACK TO INPUT OF BAP AND BLOW Fuse. Sorry, but we do not have the wire locations and colors for all vehicles, so please consult your service manual or dealer if you do not see your vehicle listed above, OR you may be able to get info from Taylor Automotive Tech 1(800) 636-6414 or retrieve information from the internet at www.nashville.net/~teklin19/manual. html, SK GN SWITCH PANELS - Note: If using @ Kenne Bell KB82068 Fuel Pump / Anti Theft Switch, the switch MUST BE BYPASSED as the switch is not rated high enough to handle the increased load {FULL TIME OPERATION OF THE BAP 8 DESIRED, SIMPLY JUMPER THE ‘TWO WiRES TOGETHER THAT GO TO THE PRESSURE VACUUM OWITCH agri emee BLACK SOU RERS ike WIRE Vacuum / Pressure nme \ Switch WIRE IN BOOST:A-PUMP HERE. (04 Pressure SenderCos ne BOOST-A-PUMP TECHNICAL INFORMATION AND INSTALLATION INSTRUCTIONS OVERVIEW ‘The Kenne Bell BOOST-A-PUMP is designed to increase the output of any fuel pump from 1% up to 80%. Itaccomplishes this by increasing the voltage approx. 5 volts (10% per vol). Itwilalso maintain this pre-set voltage or output within 1% regardless of battery voltage (within 9- 17 volt). Alitle known facts that voltage toa fuel pump can vary 10% depending onthe accessories thatare.n Lo. ighs, stereo, AC, wipers, heater, brake lights and even directional signals. The BOOST-A-PUMP immediately compensates for any subsequent voltage drop and fuel output reduction Infact, the BOOST-A-PUMP will maintain the +50% output as low as 9 volts! Yes, you can also use iton the ignition system to either increase or ‘maintain the desired voltage ifbypassing or eliminating the charging system. TECHNICAL BACKGROUND enne Bell has 37 years ofbackoround experience in hyrauic enginasring, We know fuel systems. The Kenne Bel ful ow bonchs socondto none, We have documented the flow capacities of varus fua ins fypes and sizes, ested al the currently avaliable pumps (land alone, ine booster and in tank, reguiators, ue ras, mass air metors and fiters. Countess dyno tess have been conducted on our house dyno with 2 ‘variety of fuel system combinatons. Fue! prossure and fl and air fuel ato were measured with our computorized datalogger system. The 800ST-A-PUMPIs the llest on the lng listof Kenne Bel innovations Read the folowing tecnica information. iwilhelp you to batter under. stand the dynamicsoffuel low and pressure. FLOWvs. PRESSURE Firstof al, pressure nat volume - isthe mostimportant indicator. Afuel injector with the proper pressure wil low the necessary fuel volume). Ifit ‘doesn't have the correct pressure, only THEN do you became concerned about volume, Study the pump flow graph in our iterature and you wil notice that 2s flow increases - pressure decreases. Conversely as flow (volumo) docroasos, pressure increases. Never forget that and itwill help you better understand the relationship between pumps, injectors, regulators, fuel ines, FMU/FMB's otc. EXAMPLE: (See Pump Flow Graph in literature). pump flows 881 at 40 psi. Whatis the low at 50 ps? Answer: 7BL at 50 psi. Whatis the flow at 30 psi? Answer: 97Lat 30 psl You need 1921 at 40 psi. Can't maketwith the 88L.Add a Kenne Bell SOOST-A-PUMP tothe BBL stock pumpand youhaveit INSTALLATION Installation is easy and straight forward, The BOOST-A-PUMP splices into the existing hot (+) fuel pump wire and increases the voltage to the pump (see STEPS 1 - 3). Connect to the red wires as shown. The black wires are the grounds. There is a cable that connects to the Cockpit Controllerand acable that connects o the Vacuum/Boost switch, KB89066 VACUUM SWITCH ACTIVATION (NORMALLY ASPIRATED ONLY) For non-supercharged applications, the cable connects to a vacuum switch (normally aspirated) and activates at WOT (wide open tote) an’ low vacuum (approx. 4"). Depending on how efficient your intake system is (ideal vacuum gauge reading at WOT is 0") indicating "0" or no restriction thru the fiter, hoses, throttle body and intake manifold. 2, 3", 4", 6" etc. represent varying degrees of restriction, 6” being highly restrictive. NOTE: The vacuum switch is adjustable. To alter setting tee in a vacuum gauge between the switch and an open hose. Suck on the other end of the hose. You can typically register up to 10° of vacuum. Watch the gauge neadle. You will hear the switch “alick.” The “click” the ‘contacts closing that activate the BOOST-A-PUMP. KB89067 PRESSURE SWITCH ACTIVATION (SUPERCHARGED OR TURBOCHARGED ONLY) (On supercharged or turbocharged applications, the pressure switch activates the BOOST-A-PUMP at approx. 3.5 psi. There's an optional 5 psi (cost$10) FULL TIME OPERATION We consulted the major suppliers of fuel pumps and they concurred that operating thelr purnps at the elevated voltages we use with the BOOST- ‘A-PUMP has litle if any effect on pump life EVEN IF OPERATED FULL TIME. Therefore, the BOOST-A-PUMP may be activated full ime if desired. The regulator merely retums the unused uel to the tank via the return line much the same as any larger pump would do, FMU/FMB APPLICATION FMUIFMB (fuel mangagement units or boosters) are supplied with all Kenne Bell, Vortech, Paxton, ATI, WheeleriSVO and B&M, BBK super- charger kits. These valves are installed inthe fuel retum line and merely restrictor shut ofthis ine and increase fuel pressure thereby diverting ‘more fuel thru the injectors. NOTE: Our dyno testing has determined that these FMU/FMIB devices increase fuel pressure as boost increases. Example: Mustangs with stock intank pump and 24 injectors 48 psi with boost reference. An FMLU raises the pressure to 59 psi fixed." An inline ump raises pressure to 90 psi "fixed" and the injectors go sonic and lock, Better approach would have been the stock pump and FMU at 55 ps. BOOST-A-PUMP would allow pressure to be fully adjustable between 55 to 90 psi for ideal air fuel ratio and maximum horsepower. CAUTION: ‘Typically an FMU raises fuel pressure 10 psifor every 1 psiof boostF the pump has the capacity. INLINE BOOSTER PUNPS (WITH FMU/FMB) Therefore, we donot recommend inline "booster" pumps with any FMU/FMB system. 1.) They can increase fuel pressure to dangerous levels. 2.) There is no pump flow adjustment. Fuel and pressure are FIXED and cannot be adjusted. 3.) Some injactors go "soni or “lock up™ at higher pressures negating controlby the computer. 4.)"inline* pumps are noisy Inline stand alone high capacity pumps are acceptable but be carefu big inline pumps with the FMU/FMB. Remember, the injectors must be capable of suppiying or passing all this additional fuel volume into to engine or the pressure wil increase to alarming levels. Larger injactors (increases pump volume and decteases pressure) and or eliminating the FMUIFMB (allows increased uel volume thruthe return line so lowers pressure) ora smaller pump with a Kenne Boll BOOST-A-PUMPwill reduce and better control this pressure because of the adjustability.PAGES of 5 INLINE PUMPS (WITHOUT FMU/FMB) intine pumps that donot utilize an FMU are typically nota problem as mostfuelreguletors have the low capacity to bypass te fuel not used by the jctors back to the tank va the retum ine. Two (big) stand alone pumps may flow more fuel atidle than the regulator can bypass. An abnormally il pressure that cannot be lowered with adustment indicates this condition exists. Here again the preferred setup is one (1) big pump and JO0ST-A-PUMP tiggoredby switch hat eliminates althathigh volume aisle. FUEL TEMPERATURE There is one other consideration - fuel temperature. The more fuel the pump discharges the higher the fuel temperature. An inline booster pump that s activated full ime forces al the excess fuel fiow thru the regulator and return lin heating the fuel in the process. Yet another reason the Kenne Bell BOOST-A-PUMP activated by a pressure switchs the preferred set up. REGULATORS kenne Ball was the first to manufacture a true billet aluminum adjustable reguiator. The Syclone/Typhoon, Buick Turbo V6's and many other vehicles do not use the FMU/FMB's, Standard equipment for these vehicles is an adjustable pressure regulator. Set the icle with vacuum hose on, Prossure will ncrease 8 psi at 0 vacuum and increase proportionally with boost. Example #1. 30 psi ile, 38 psi at O vacuum and 48 psi at 10 psi ‘boost. Example#?2. 40 pslidle, 48 psi at and 58 psi at 10 psiboost-or 68 psi at 20 psiboost. These numbers are attainable only ifthe regulators ‘boost referenced (vacuum line connected). Ifthe vacuum line is not connected, expect 8 psi more at ide, the same at 0 vacuum and minus the boost psiat WOT. On naturally aspirated applications removing the vacuum line does not affect WOT fuel pressure - only idle pressure by 8 ps “Turbochargedor supercharged engines can experiment with an irfuol ato by varying WOT pressure with this vacuum line. 8 psican resuttin up to. 6AF/R variancos. FORD FUEL PRESSURE ‘DOITWITHACHIP Ford pressure regulators work best at stack pressure (30 psi with vacuum line on). No, this is not a misprint. The EEC looks at both the idle and WOT fuel tablos fo adjust fuel. Therefore increasing fuol prossure holps only tomporariy -untithe EEC sats WOT fuel basad on idle pressure. It bogins adjusting both back to the pre set air fuel ratio programmed in he EEC or the Kenne Bell SWITCH CHIP program. However, at some point, ‘as pressure is increased, the EEC Is unable to trim’ back the rich misdure at idle and WOT. Then again, iFidle remains at the stock 30 psi seting WOT pressure can be increased and the mixture richened without the EEC trimming either. That is the principle behind the FMU/FMB on all ‘supercharger kits curenly available. Emissions are not affected as the richening only occurs at WOT. The best approach sto contro air fuel ratio with a Kenne Bell SWITCH CHIP ora stand alone systom, such as the DF. The Kenne Boll SWITCH CHIP does not alter air fue ratio atidle, part ale etc. -only WOT. And NEVER try to “adjust out idle up and down surge with the ide screw. The alr fuel ratio ate is OFF (excessively lean 2h) if the engine is “hunting.” Its trying o adjust fora poorly calibrated idle mixture. Lower the pressure at ide to 30 psi and back off the idle screwto the factory setting. Sight adjustments may be made without adverse effects, ‘SPEED DENSITY ‘Speed Density System Ford cars and trucks use pre-mapped fuel tables in both open and closed loop so raising fuel pressure is sensitive as ‘compared to the Mass Air Systems which rely onal flow (mass) to calibrate uel delivery. Therefore, the Kenne Bell BOOST-A-PUMP is an ideal approach for both naturally aspirated and supercharged vehicles (with and without FMU/FMB). Because of its less sophisticated computer, the ‘Syclone/Typhoon Speed Density System is nots sensitive to idle pressure, EMISSIONS ‘Since the Kenne Bell BOOST-A-PUMP is only activated at WOT (open loop) fue! pressure atidle and part throttle cannot possibly be affected on ‘any vehicle. Even if activated full imo at maximum 50% increase we have nat seen evidence of elavatad fuel pressure on any of the vehicles we've tested. Nevertheless, 50 State Legal Status has been applied for. FUEL PRESSURE GAUGE - GETONE! ‘Youcan't determine engine RPM without a tach. You can'tdetermine engine temperature without a temperature guage. You can'tdetermine boost, without a boost gauge. And there is certainly no way you can determine fuel pressure without a fuel pressure gauge. GET ONE. One cannot tune and trouble shoot fuel injected car without fuel pressure gauge. ‘TROUBLESHOOTING BOOST-A-PUMP DOESN'T ACTIVATE ‘Checkallwire connections ‘Check ground. MUST BE GOOD GROUND CONNECTION. Faulty pressure switch. Bypass the switch by connecting the two wires together (short together-thereis no voltage on ths circu) DONOT GROUND THESE WIRES. Now check the red OUTPUT + wire and GROUND with a VOM. Turn Cockpit Control to MAX. Voltage should readatleast 16 vats. Check forblown fuse. See inline fuse in red INPUT + wire (cary a spare with you atalltimes). )OST-A-PUMP CYCLES "ON" &"OFF" ‘sult intornal crcultbreaker (separate from the fuso) in BOOST-A- PUMP modulo is being triggered because of overload. Operating rating s 15.amps (maximum peak 20 amps, 40 amps for-2 Models).Hi Tech Performance Products 1996 AND UP MUSTANG GT 2V AND COBRA 4V BOOST-A-PUMP WIRING ‘shuts off voltage to | the Fuel Purp in the ‘ealety device that event of a calision, RUN CABLE TO INSIDE OF CAR ‘AND MOUNT TTOINTAKE (vacuum switch) or ‘SUPERCHARGER 10743 Bell Ct. Rancho Cucamonga, CA 91730 (Orders (908) 941-6646 Tech (909) 941-0985 Fax (909) 944-4883Coro Hi Tech Performance Products ALTERNATE INSTRUCTIONS FOR RUNNING NEW WIRING TO BOOST-A-PUMP™ Lp wire To OLD FUEL {CuFAND USE 10 ruer ‘ PUMP PUMP RELAY a UN COL OF NeW BATTERY Cosa Lr NEW NeW FUEL so Aue 10 or 12 puMe RELAY AWG WIRE wininue) = 10743 Bell Ct, Rancho Cucamonga, CA 91730 Orders (909) 941-6648 Tech (909) 941-0985 Fax (909) 944.4883, ( {Torcumion _, SPOUSE ‘SWITCH Fuet pum RELAY com. ECM. FuELpu 1 “GwtaNR) acl ruck pume neta Hates estima, PAST conten re BuLkHeAo SHS Boy CONNECTOR 150 BUDHERD ConnectoR ‘NDERNOOD TIE Int CHART A-5 FUEL PUMP RELAY CIRCUIT 4.3L TURBO (VIN Z) SYCLONE AND TYPHOON (PORT) When the ignition switch is turned “ON,” the Electronic Control Module (ECM) will activate the fuel pump relay and run the in-tank fuel pump. The fuel pump will operate as long as the engine is cranking or running Circuit Description: and the ECM is receiving ignition reference pulses. If there are no reference pulses, the ECM will shut "OF the fuel pump within 2 seconds after key “ON.” Should the fuel pump relay or the 12V relay drive from the ECM fail, the fuel pump will be run through an oil pressure switch back-up circuit Test Description: Numbers below refer to circled, ‘numbers on the diagnostic chart. 1. This test will determine if the oil pressure switch is closing and supplying voltage to the fuel pump ‘when the relay is not functioning. 2, This test will determine if the oil pressure switch isstuck open, Diagnostic Aids: An inoperative fuel pump relay can result in long. cranking times, particularly if the engine is cold or engine oil pressure is low. The extended crank period is caused by the time necessary for oil pressure to build enough to close the oil pressure switch and turn "ON" the fuel pump. wa TREES eee ‘ ali e880.BOOST-A-PUMP Supplement for '03 Cobra To be used with BAP instructions. See general BAP instructions included with BAP for specific installation. ~ This page is meant as an overview explaining where to mount the BAP and exactly which wire to tap into. BAP SETTING ‘Set BAP controller based on supercharger pulley size. NOTE: If you have a larger crank pulley than stock, use the pulley ratio or peak boo: Fuel psi at wide open throttle should be 85 psi at 6500RPM. 1, The BAP will be mounted in the trunk behind plasti/fele Pay attention and don't drill through the fender when drilling hole for BAP 2. There is a wire loom leading to fuel pump control module, slice, tape and pull back loom. 3. Locate brown wire with pink stripe coming from fuel pump control module, this is the wire leading directly to the twin intake pumps. Cut this wire approximately 2-3 inches from connector. ig from fuel pump control module, 4. Install heat shrink on red fused wire of BAP (input) splice to wire co solder wires and heat shrink. 5. Splice, solder, and heat shrink non-fused output wire from BAP to brown with pink wire leading to pump. 6. Install ground lug on black ground wire and attach chassis ground location in fender well. Close to fuel pump control module. Be sure to solder ground lug to insure against corrosion, 7. Run controller wire to desired location and mount control box. Shown installed in trunk, this is anice place to mount it. (no one can re-adjust your fuel by accident) 8. Run switch wire through car inside under plastic lower trim panel to engine compartment. 9. Hook switch wire to boost switch and tee into boost line leading to fuel pressure sensor from discharge ‘manifold. 10. Replace stock 20A fuse inn power distribution center (under hood) with 30A for fuel pump. Refer to owners manual for correct fuse location. 11. Overall this makes for a very clean installation. Ziptie all loose wires. Re-loom fuel pump control module and tape up with electrical tape. 12. Set BAP controller according to the table above. Page 40 of 43