INSTALLATION MANUAL FOR 24 VALVE 5.
Adjustable Regulator MOUNTS IN THE SAME LOCATION AS THE OE TRANSFER PUMP
OVERVIEW Welcome to the Raptor™ FRRP Fuel Pump The Raptor™ FRRP-150 Fuel Pump is a Premium high output 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-150 is for stock 5.9L Cummins Diesels.
Parts List QTY DESCRIPTION Part Number 1 RAPTOR™ FRRP FUEL PUMP 1 Mounting Hardware Kit 1 Customer Service Oring Replacement Kit 1 ¾”-16 Oring Boss X -8 JIC Fitting 4A-1-02-08-08-S 2 Fitting, ½” Push Lock X -8 Female JIC Swivel Fitting, -8 Male JIC x -8 Female JIC Swivel, 90° Elbow 4A-1-09-08-08-B 2 2 Output Hose Assembly 2 12mm X ½” Male SAE J2044 Quick Connect Fitting Sealing Washer (installs on WAP102 fitting and factory inlet banjo) 12mm X -8 Male JIC fitting 4 1 FRRP-150 901-61-010
ILLUSTRATION OF COMPONENTS
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.
INSTALLING THE FRRP-150 1. Replace the 2 original sealing washers on the stock banjo fitting with the 2 new ones provided (part# 1P-5-DS). 2. 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. 3. Install the Boss O-ring fitting (part# 4A-1-02-08-08-S) into the outlet port of the FRRP and tighten firmly. 4. Firmly tighten the FRRP to the stock bracket using the hardware supplied. See Fig 2 Fig 2 5.
INSTALLING THE FRRP-150 CONTINUED 7. Cut the open end of the “Output Hose Assembly” to the desired length and install the ½” push lock x -8 swivel (part# 4A-1-09-08-08-B) into the end. See Figures 6 & 7 Figure 6 Lubricate the fitting with oil. Figure 7 Push the hose completely on the barb. 8. Loosely install the male end of the 90° elbow (part# 4A-2-04-08-08-S) on the hose assembly. 9. Loosely install the female end of the 90° to the outlet fitting of the FRRP previously installed in step 3. 10.
INSTALLING THE BIG LINE KIT 1. Remove and discard the fuel hard line that runs between the filter canister and the injection pump. 2. Install the seal washer and “WAP 102” male quick connect to the inlet port of the injection pump. (See Figure 8) WAP 102 and Seal Washer Figure 8 3. Install the 12mm X -8 male JIC fitting with seal washer into the outlet port of the fuel filter canister. Outlet Port Figure 9 Figure 10 4.
INSTALLING THE BIG LINE KIT 5. If required, cut the open end of the hose assembly to the desired length and install the ½” push lock x -8 swivel (part# 4A-1-09-08-08-B) into the end. See Figures 12 & 13 Figure 12 Lubricate the fitting with oil. Figure 13 Push the hose completely on the barb. 6. Loosely install the male end of the 90° elbow (part# 4A-2-04-08-08-S) on the hose assembly. 7. Route the hose assembly in a fashion to prevent kinking or chaffing. 8.
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-150 Fuel Pump. 2. While the Raptor™ FRRP-150 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.
