1. Product Overview
The Radium Engineering Fuel Pump Install Kit (20-0276-00) is designed to facilitate the installation of specific 39mm aftermarket fuel pumps into Porsche 911/996 vehicles. This kit includes a precision-machined 6061-T6 CNC billet aluminum sleeve and necessary electrical components, ensuring a plug-and-play installation without requiring cutting, drilling, or grinding.
The aluminum sleeve is engineered to increase the effective diameter of a 39mm pump to mimic a 43mm pump, allowing it to securely fit within the factory fuel pump hanger. A machined rib on the sleeve ensures correct orientation and proper seating of the fuel filter sock.
Image 1.1: Components of the Radium Engineering Fuel Pump Install Kit.
2. Important Safety Information
Always prioritize safety when working with automotive fuel systems. Fuel is highly flammable, and improper handling can lead to serious injury or fire.
- Ensure the vehicle's battery is disconnected before beginning any work on the fuel system.
- Work in a well-ventilated area, away from open flames, sparks, or other ignition sources.
- Wear appropriate personal protective equipment (PPE), including safety glasses and fuel-resistant gloves.
- Have a fire extinguisher readily available.
- Relieve fuel system pressure before disconnecting any fuel lines.
- Dispose of fuel and contaminated materials according to local regulations.
- If unsure about any step, consult a qualified automotive technician.
3. Package Contents
Verify that all components are present and undamaged before proceeding with installation:
- 1x 6061-T6 CNC Billet Aluminum Sleeve (Green)
- 1x Hose Clamp (for securing the pump to the sleeve, if applicable)
- Electrical Connectors (for plug-and-play wiring)
- Heat Shrink Tubing (for electrical connections)
4. Setup and Installation
4.1. Tools and Materials Required
- Basic hand tools (wrenches, screwdrivers, pliers)
- Fuel line disconnect tools (if necessary for your vehicle)
- Wire crimpers/strippers
- Heat gun (for heat shrink tubing)
- Clean rags and absorbent pads
- New fuel pump (39mm diameter, not included)
4.2. Pre-Installation Notes
- This kit is specifically designed for 39mm diameter fuel pump bodies. Measure your aftermarket pump's outside diameter to confirm compatibility.
- Refer to your vehicle's service manual for specific instructions on accessing and removing the factory fuel pump assembly.
4.3. Installation Steps
- Prepare Vehicle: Safely lift and support the vehicle. Disconnect the negative terminal of the battery. Relieve fuel system pressure.
- Access Fuel Pump: Follow your vehicle's service manual to safely access and remove the existing fuel pump assembly from the fuel tank.
- Remove Old Pump: Carefully remove the old fuel pump from the hanger assembly. Note the orientation of the fuel filter sock.
- Install Sleeve onto New Pump: Slide the Radium Engineering billet aluminum sleeve over the body of your new 39mm aftermarket fuel pump. Ensure the sleeve is fully seated and the machined rib aligns with the designated slot or feature on the fuel pump hanger. This rib is crucial for properly locating the filter sock.
- Secure Pump (if applicable): If your pump requires a clamp to secure it within the sleeve or hanger, use the provided hose clamp or appropriate fastening method.
- Electrical Connections: Using the provided electrical components (connectors and heat shrink tubing), make the necessary electrical connections to integrate the new fuel pump into the vehicle's wiring harness. This kit is designed for plug-and-play installation, minimizing the need for cutting or splicing. Ensure all connections are secure and properly insulated with heat shrink tubing.
- Reassemble Hanger: Carefully reassemble the fuel pump and sleeve assembly into the fuel pump hanger, ensuring the filter sock is correctly positioned and not pinched.
- Reinstall Assembly: Reinstall the complete fuel pump hanger assembly back into the fuel tank, ensuring all seals and gaskets are properly seated to prevent leaks.
- Reconnect Fuel Lines and Electrical: Reconnect all fuel lines and electrical connectors to the fuel pump assembly. Double-check all connections for tightness and security.
- Final Checks: Reconnect the vehicle's battery. Turn the ignition to the 'ON' position (without starting the engine) for a few seconds to prime the fuel system. Check for any fuel leaks around the newly installed components. Repeat priming if necessary.
- Test Operation: Start the engine and carefully check for proper fuel pressure and any signs of leaks.
5. Operation
The Radium Engineering Fuel Pump Install Kit itself does not have an 'operation' mode. Its function is to provide a secure and correctly oriented mounting solution for a compatible 39mm aftermarket fuel pump within the Porsche 911/996 fuel tank. Once installed, the kit enables the proper operation of the aftermarket fuel pump, ensuring consistent fuel delivery to the engine as designed by the fuel pump manufacturer.
6. Maintenance
The Radium Engineering Fuel Pump Install Kit is designed for long-term durability and typically requires minimal maintenance. However, periodic inspection of the fuel system components is recommended.
- Visual Inspection: During routine vehicle maintenance, visually inspect the fuel pump assembly area for any signs of fuel leaks, corrosion, or damage to the electrical connections.
- Connection Integrity: Ensure all electrical connections remain secure and free from corrosion.
- Fuel Filter: Regularly check and replace your fuel filter as recommended by your fuel pump or vehicle manufacturer to prevent strain on the fuel pump.
7. Troubleshooting
If you encounter issues after installing the fuel pump kit, consider the following common troubleshooting steps:
- Fuel Leaks: Immediately shut off the engine. Re-check all fuel line connections and the seating of the fuel pump assembly in the tank. Ensure all seals and gaskets are correctly installed and undamaged.
- No Fuel Pressure / Pump Not Running:
- Verify all electrical connections are secure and properly crimped.
- Check relevant fuses and relays in the vehicle's electrical system.
- Ensure the fuel pump itself is functioning correctly (this kit does not include the pump).
- Incorrect Fuel Pump Fitment: If the pump does not fit securely, re-verify that your aftermarket fuel pump has a 39mm diameter. The sleeve is specifically designed for this size.
- Filter Sock Misalignment: If fuel flow issues occur, ensure the machined rib on the sleeve correctly located the fuel filter sock and it is not kinked or obstructed.
For persistent issues, it is recommended to consult a professional automotive technician or contact Radium Engineering customer support.
8. Specifications
| Model Number | 20-0276-00 |
| Brand | Radium Engineering |
| Material | 6061-T6 CNC Billet Aluminum |
| Compatible Pump Diameter | 39mm (aftermarket pumps) |
| Mimics Pump Diameter | 43mm (for factory hanger fitment) |
| Vehicle Compatibility | Porsche 911/996 |
| Item Weight | 1.32 pounds (approx.) |
| Product Dimensions | 4.7 x 4.2 x 4.1 inches (approx.) |
9. Warranty Information
Radium Engineering products are manufactured to high standards. For specific warranty terms and conditions pertaining to the Fuel Pump Install Kit (20-0276-00), please refer to the official Radium Engineering website or contact their customer service directly. Keep your proof of purchase for any warranty claims.
10. Customer Support
For technical assistance, installation questions, or product inquiries, please contact Radium Engineering customer support through their official website or the contact information provided with your purchase. When contacting support, please have your product model number (20-0276-00) and purchase details readily available.
Radium Engineering Official Website: www.radiumauto.com
