INSTALLATION MANUAL #36 FOR 24 VALVE 5.9L CUMMINS POWERED DODGE TRUCKS 1998 ½ THROUGH 2002 MODEL FRRP-100 FACTORY REPLACEMENT RAPTOR PUMP READ THESE INSTRUCTIONS THOROUGHLY BEFORE BEGINNING INSTALLATION PureFlow AirDog 705 MAUSOLEUM ROAD SHELBYVILLE, IN 46176 1-877-421-3187 WWW.PUREFLOWAIRDOG.
Adjustable Regulator MOUNTS IN THE SAME LOCATION AS THE OE TRANSFER PUMP 2
OVERVIEW Welcome to the Raptor™ FRRP Fuel Pump The Raptor™ FRRP-100 Fuel Pump is a Premium replacement lift pump for the Dodge Cummins 24 Valve 5.9L diesel engine. A complete installation kit is included. The output pressure for the 5.9L 24 Valve Cummins engine is factory set at 14/16 PSI. Pressure and flows are approximate as they will vary with fuel temperature and as the brushes wear in. The FRRP-100 is for stock 5.9L Cummins Diesels.
QUICK CONNECT COMPONENT OVERVIEW Provided in this kit is an OE style quick connection system. This system allows a quick, clean, and professional install. SAE J2044 Quick Connect System The SAE J2044 quick connect system is the most commonly used system in the automotive industry. The images below show the formation of SAE J2044 connection. To connect the assemblies, simply insert the male end form into the mating female connector. Push firmly until you hear it “click” into place.
Parts List QTY DESCRIPTION PART NUMBER 1 Factory Replacement Raptor™ Pump (FRRP) FRRP-100 Mounting Hardware Kit 901-61-0102-FRRP 1 Customer Service Oring Replacement Kit 906-05-0100 1 1/2” Male QC x 3/4-16 ORB 08J2044-3/4UNF 1 2ft of Fuel Line HS02 2 1/2" 90° Hose Quick Connect Fitting FQC1290 1 1 3 12mm X ½” Male SAE J2044 Quick Connect Fitting Sealing Washer (installs on WAP102 fitting and factory inlet banjo) WAP 102 1P-5-DS 5 IMAGE
ILLUSTRATION OF COMPONENTS 6
INSTRUCTIONS REMOVING THE STOCK PUMP FIG 1. (SOURCE: alldatapro.com) 1. Disconnect the electrical connector. Reference #6 of Fig. 1 2. Remove the banjo fitting on the inlet side of the stock fuel pump. Reference #4 of Fig 1. Do not discard this banjo fitting. It will be reused. 3. Remove the banjo fitting from inlet of the filter canister. 4. Remove the fuel line support from the mounting bracket. Reference #3 of Fig 1. 5. Remove the 3 mounting nuts at the top of the bracket. Reference #2 of Fig 1. 6.
Assembling the Fuel Lines This kit includes a length of fuel line and separate fuel line ends to allow for much cleaner looking installations! Assemble the fuel lines as you install them. You won’t want to pre-assemble the hoses or your lengths may be off. 1. Take the fuel line end and lubricate the barbed end with clean motor oil (Figure 2) and press it into the fuel line (HS02) until all three barbs are covered (Figures 3 and 4). The fuel line end should look like Figure 4.
INSTALLING THE FRRP-100 1. Replace the 2 original sealing washers on the stock banjo fitting with the 2 new ones provided (part# 1P-5-DS). And firmly tighten the factory fuel supply line in the inlet port of the FRRP using the factory banjo fitting. The factory support bracket is no longer used. 2. Install the 08J2044-3/4UNF fitting in the port labeled “Out,” using a 7/8" Wrench. Reference Figure 5. Figure 5 4. Firmly tighten the FRRP to the stock bracket using the hardware supplied. See Fig 6 Figure 6 5.
INSTALLING THE FRRP-100 CONTINUED 6. Assemble one end of the hose (Reference the fuel line assembly section) using fuel line end FQC1290 and plug it into the WAP102 fitting installed in the filter canister “inlet” port in the previous step. A “click” will be heard once the fitting is properly connected. FQC1290 Figure 8 HS02 7. Run the fuel line to the port in the FRRP labeled “Out” and cut the fuel line to length.
INITIAL START PROCEDURE 1. Turn the starter key to the on/run position. Note: It may be necessary to bump the starter for the ECM to energize the Raptor™ FRRP-100 Fuel Pump. 2. While the Raptor™ FRRP-100 Fuel Pump is on, bleed the fuel line to the filter canister by disconnecting the quick connect at the canister. As soon as the line is purged of air and fuel is observed, quickly reinstall the female quick connect. A click will be heard when properly installed. 3.
PUREFLOW AIRDOG 4 YEAR LIMITED EXPRESS WARRANTY FOR Raptor™ FRRP-100 IMPORTANT NOTICE TO ACTIVATE YOUR PURFLOW AIRDOG WARRANTY, YOU MUST COMPLETE AND MAIL YOUR WARRANTY CARD TO PUREFLOW AIRDOG WITH A COPY OF YOUR ORIGINAL SALES RECEIPT WITHIN 30 DAYS OF PURCHASE. FAILURE TO COMPLETE AND SUBMIT YOUR WARRANTY CARD WILL RESULT IN A WARRANTY PERIOD OF THE COVERED PRODUCT TO ONE (1) YEAR FROM THE DATE OF PURCHASE.
rights other than those expressly written herein. This Warranty shall not be extended or varied except by a written instrument signed by SELLER and BUYER. IN THE EVENT THAT THE BUYER DOES NOT AGREE WITH THIS AGREEMENT, THE BUYER MAY PROMPTLY RETURN THE PRODUCT, IN A NEW AND UNUSED CONDITION, WITH A DATED PROOF OF PURCHASE, TO THE PLACE OF PURCHASE WITHIN THIRTY (30) DAYS FROM THE DATE OF PURCHASE FOR A FULL REFUND.
