AEM High Flow Inline Fuel Pump 501005 User Manual

							 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Part Number 50-1005 
 
 
 
 
 
 
WARNING: 
! 
This installation involves your vehicle’s fuel system and is not 
for the mechanically challenged! If you are not mechanically 
inclined or do not understand the procedures listed in the 
instructions please do not attempt the installation. Refer the 
installation to a reputable mechanic. 
 
 
 
 
 
 
 
 
 
 
AEM Performance Electronics 2205 126th Street Unit A, Hawthorne, CA. 90250 Phone: (310) 484-2322 Fax: (310) 484-0152 http://www.aemelectronics.com Instruction Part Number: 10-1005  2014 AEM Performance Electronics 
 
380 LPH FUEL PUMP 
Installation Instructions  
						

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CAUTION! 
Installation of the AEM Fuel Pump requires the installer to handle gasoline. It is 
imperative that all work is carried out in a well-ventilated area and a fire 
extinguisher rated for gasoline fires is within easy reach of all personnel working 
on the fuel system. Extinguish all open flames, prohibit smoking, and eliminate all 
sources of static electricity or any other source of ignition BEFORE proceeding 
with installation. 
Wear protective clothing, goggles, and gloves rated for gasoline. Contact with 
gasoline is hazardous to your health; ensure that you are well protected from 
contact with gasoline. 
 
The AEM Fuel pump is ONLY compatible with gasoline. The AEM 380 LPH High 
Flow Fuel Pump can be used as an in tank pump or an externally mounted pump. 
Ensure that the wiring to the pump is rated for at least 25 amps and the insulation 
is rated for automotive use. Use a fused circuit for the pump with a fuse rated at 
25 amps. 
 
AEM 380lph High Flow Fuel Pump Kit Contents; 
 
Quantity Description 
      1  380lph High Flow Fuel Pump 
      1  -6 to -8 Check Valve 
 2  Electrical Ring Terminals  
      2  Terminal post nuts and lock washers 
      2  Terminal post boots 
      1  Instructions 
Optional accessories for AEM 380 lph High Flow Fuel Pump 
 -10 Inlet port Fitting  AEM PN: 50-200-10 
 -10 Inlet Filter   AEM PN: 50-200-11 
 -6 Discharge Fitting  AEM PN: 50-200-06 
 -6 to -8 adaptor   AEM PN: 50-200-86 
 -6 to -8 adaptor with check AEM PN: 50-200-08 
This fuel pump is intended for electronic fuel injection systems only. It is not suitable for carbureted 
engines. The AEM 380 lph High Flow Fuel Pump designed to be used externally or as an in tank 
installation. A pre-filter rated at 100 microns MUST be used. Failure to use a suitable pre filter will result in 
premature failure of the pump. AEM -10 Inlet Filter provides an easy solution for in-tank pump protection. 
 
Pump Flow and Test Information 
 
Every AEM fuel pump is flow tested before it leaves the factory to ensure that it flows nominal 380 LPH @ 
43 PSI.* The flow chart presented below is the result of flow testing 20 fuel pumps, eliminating the highest 
and lowest flowing samples and averaging the balance of the flow data. The data presented is flow in 
pounds per hour (PPH), and supported power at various fuel pressure levels. This test data is generated 
using a pre filter with a 100 micron rating, AEM 380lph High Flow Fuel Pump, AEM Universal High 
Volume Fuel Filter, a McMillan Precision Flow Meter and a -8 return valve. The pump voltage is 13.5V. 
Note that actual flow will be different at the engine because of losses through the balance of the fuel 
delivery system. The flow values presented are with the optional -6 discharge fitting. The fuel flow will be 
lower when the check valve is used.  
 
 
  
						

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Fuel Hose and Routing and Installation 
 
IMPROPER FUEL HOSE ROUTING AND INSTALLATION DRAMATICALLY INCREASES THE RISK OF 
FIRE.  BE SURE TO FOLLOW THE FOLLOWING GUIDELINES: 
 It is important to ensure that the hoses or lines for the fuel delivery system are clean, not kinked, 
do not pass hot exhaust components and are terminated correctly. Inadequate fuel delivery often 
is the cause of calibration errors that may be detrimental to engine life. 
 NEVER route fuel hoses through the interior of a car. 
 Whenever possible, use a delivery tube to make the connection from the pump discharge to the 
filter in the front of the car. 
 The lines should be rated to withstand at least twice the maximum pressure of the EFI system. In 
the case of the AEM 380 lph High Flow Pump, minimum burst pressure should be no less than 
250 PSI 
 When routing fuel lines, it is imperative that they are protected from road hazards and the exhaust 
system heat. The fuel line should NEVER be routed near battery cables. Use clamps to secure 
AN hose every 15 inches, or 24 inches if a rigid tube is used. 
 Use the following table will help you determine which hose size is correct for your application. 
These sizes are based on a nominal fuel pressure of 43 psi. 
 
Fuel Delivery Hose Sizes 
Gasoline Powered Engines 
 
Up to 499 HP .344” hose -6AN 
500 - 799 HP .437” hose -8 AN 
900 – 1100 HP .562” hose -10 AN 
Note that this table should be used for typical passenger car applications. For custom applications the 
hose run length and complexity of the hose routing will affect fuel delivery. To determine the capability of 
200.00
250.00
300.00
350.00
400.00
450.00
35404550556065707580859095100105110115120
Fuel Flow in LPH
 
Fuel Pressure PSI 
AEM 380 lph Fuel Pump Flow at 13.5V Gasoline 
Ltr/Hr W/O check ValveLtr/Hr W check Valve 
						

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the fuel delivery system, measure the output of the system by activating the pump with the vehicle 
operating voltage and measure the volume of fuel delivered in 1 minute. Multiply the delivered value by 
60 to get volume/hr.  
 
 
Electrical Requirement 
 
The supply voltage will affect the fuel delivery of the AEM Fuel Pump. The typical electrical system on 
modern cars is between 13.2 – 14.2 volts. Although the AEM fuel pump will run at lower voltages the flow 
will be lower. Ensure the voltage is 13.5V at the pump. The current requirement is a FUSED circuit 
capable of conducting 25 amps. Failure to use a fuse WILL cause a fire hazard in the event the pump 
fails from contamination.The correct wire size will be determined by the length of wire, the wire type and 
the resistance of any terminals, splices or solder joints in the electrical or ground supply. The ground is 
equally important and the preferred ground is to route the ground wire to a star ground source that is 
directly attached to the battery negative post. The minimum wire gauge is 14ga. TXL wire. Twelve feet 
(12’) of TOTAL CIRCUIT length (power & ground) 12 ga. is required and Twenty feet (20’) 10 ga. is 
required. 
 
Before wiring the pump to the electrical system make sure the polarity is correct. Connecting the pump 
with reverse polarity will damage the pump and will void the warranty. The pump has markings in the 
discharge end cap at the fitting boss to indicate polarity, Red is positive (+) and Blue is negative (-). 
 
Post installation inspection 
 
BEFORE starting the engine, ensure there are no leaks at any point in the fuel system. This pump is 
capable of generating more than 125 PSI fuel pressure so excellent fuel system integrity is required. 
Check every connection point visually and mechanically. While the system is powered up, move fuel 
hoses to ensure all fittings are seated correctly. 
 
 
Warranty 
Advanced Engine Management Inc. warrants to the consumer that all AEM Electronics products will be 
free from defects in material and workmanship for a period of twelve months from date of the original 
purchase. Products that fail within this 12-month warranty period will be repaired or replaced when 
determined by AEM that the product failed due to defects in material or workmanship. This warranty is 
limited to the repair or replacement of the AEM part. In no event shall this warranty exceed the original 
purchase price of the AEM part nor shall AEM be responsible for special, incidental or consequential 
damages or cost incurred due to the failure of this product. Warranty claims to AEM must be 
transportation prepaid and accompanied with dated proof of purchase. This warranty applies only to the 
original purchaser of product and is non-transferable. All implied warranties shall be limited in duration to 
the said 12-month warranty period. Improper use or installation, accident, abuse, unauthorized repairs or 
alterations voids this warranty. AEM disclaims any liability for consequential damages due to breach of 
any written or implied warranty on all products manufactured by AEM. Warranty returns will only be 
accepted by AEM when accompanied by a valid Return Merchandise Authorization (RMA) number.  
Product must be received by AEM within 30 days of the date the RMA is issued. 
Please note that before AEM can issue an RMA for any electronic product, it is first necessary for the 
installer or end user to contact the tech line at 1-800-423-0046 to discuss the problem.  Most issues can 
be resolved over the phone.  Under no circumstances should a system be returned or a RMA requested 
before the above process transpires. 
AEM will not be responsible for electronic products that are installed incorrectly, installed in a non-
approved application, misused, or tampered with. In the case of the AEM Fuel Pump, incorrect polarity 
(+&- wires crossed) will not be warranted.  
Proper fuel filtration before and after the fuel pump are essential to fuel pump life. Any pump returned with 
contamination will not be warranted.  
 Any AEM electronics product can be returned for repair if it is out of the warranty period. There is a 
minimum charge of $50.00 for inspection and diagnosis of AEM electronic parts. Parts used in the repair 
of AEM electronic components will be extra. AEM will provide an estimate of repairs and receive written or 
electronic authorization before repairs are made to the product. 
 
Need additional help?  Contact the AEM Performance Electronics tech department at  
1-800-423-0046 or email them at [email protected].