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Operating and Installation Instructions
This product is to be installed only by persons knowledgeable in the repair and modification of vehicle fuel systems
and general vehicle systems modification. Only a qualified technician or mechanic who is aware of applicable
GASOLINE AND OTHER FUELS ARE FLAMMABLE AND CAN BE EXPLOSIVE!
Perform the installation in a well ventilated location only to minimize the build up of fuel vapors. NO open flames,
smoking or other sources of ignition are to be present during installation, to prevent fire or explosion that can cause
serious injury or death. Grinding, cutting, and drilling must be performed with care to prevent ignition. Draining and
removal of all fuel and ventilation of vapors in vehicle and fuel system is recommended when performing such
procedures. Proper eye and personal protection is required at all times during installation.
The Vehicle's fuel system may be under pressure! Do not loosen any fuel connections until relieving all fuel system
pressure. Consult an applicable service manual for instructions to relieve fuel system pressure safely.
Application:
This Installation Kit is intended to work with Fuelab
instructions included with Fuelab
the use of this Installation Kit. This Installation Kit is also intended to be used for replacement of OEM lift pump
systems that are originally installed on vehicle. This kit applies to Dodge Cummins
including the years of 2005-2013. If this Kit is not correct, please contact your Fuelab
replacement or selection of an appropriate Installation Kit.
Product Contents:
Verify the contents of this box, against list of components below and on the next sheet, to ensure that nothing is
missing. Contact your Fuelab
installation since Fuelab
designed for designated vehicles, vehicle manufacturers routinely change production components, even during the
same production year. Please contact Fuelab
that are incompatible as described within these instructions.
ITEM
P/N
1
FL500
2
FL375
3
PORB108
4
PORB88
5
PORB86
6
M1208
7
POE8
8
QC375
9
WCL500
10
WCL375
11
CBT6
12
551770
13
EPH17-3
DTK2
14
CWRAP
16
2005-2013 Dodge Cummins
safety procedures should perform the installation of this product.
Velocity Series 200 Fuel System, to complete this set of instructions pertaining to
®
distributor immediately for replacement. You may have extra parts left over after
®
has included extra parts for all years of the application described. While this kit is
®
if the particular vehicle has different descriptions or components
®
Fuel Line, 1/2" , Superflex
Fuel Line, 3/8" , Superflex
10 ORB x 1/2" Push-lok® adapter, Steel
08 ORB x 1/2" Push-lok® adapter, Steel
08 ORB x 3/8" Push-lok® adapter, Steel
12mm x 08 MJIC adapter w/seal
Push-lok® elbow, 1/2"
3/8" QC for return
Clamp for Inlet Straining Filter
Clamp for return connection
Cable Ties, Nylon 5"
Inlet Straining Filter
Extended pump harness
Draw Tube Kit 1/2" Push-lok®
Convoluted Plastic Wire Harness Wrap
Model Number 20106
C
A
U
T
I
O
N
!
C
A
U
T
I
O
N
!
W
A
R
N
I
N
G
!
W
A
R
N
I
N
G
!
Velocity Series 200 Fuel System, Model 30303. Consult
®
Description
200 Installation Kit
®
Diesel Vehicles, between and
®
distributor immediately for
®
147220126, No Rev
Sheet 1 of 14
Qty
15'
7'
1
1
1
1
1
1
2
1
6
1
1
1
11'
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Summary of Contents for Fuelab 20106
- Page 1 This kit applies to Dodge Cummins Diesel Vehicles, between and ® including the years of 2005-2013. If this Kit is not correct, please contact your Fuelab distributor immediately for ® replacement or selection of an appropriate Installation Kit.
- Page 2 2x 9 6x 11 Check above photo and list shown on previous page, to ensure no components are missing or damaged. Contact your Fuelab distributor immediately for replacement. ® Some items listed in these instructions are included in Lift Pump / Filtration System, sold separately (reference sheet 1, under Application).
- Page 3 (see diagram on previous sheet as well as Contents List on the first sheet). Also inventory and lay out all parts of the Lift Pump / Filtration System (sold separately, shown below – Reference Model 30301). The System Bracket (item S2) attaches to the Lift Pump / Filtration System (item S1) as shown below. Fuelab ®...
- Page 4 Many of these systems can include the addition of one or more filters similar in appearance to the filter used on the Fuelab Model 30301 Fuel System (companion fuel system for this installation kit). Some other modifications to the fuel system can also include the removal of the OEM Filter housing as well as the removal of the OEM Lift Pump.
- Page 5 OEM standards in performance and reliability. This installation kit allows the use of the OEM Filter Housing (in addition to the filters supplied with the Fuelab Model 30301 Lift Pump / Filtration System (Sold Separately). Some vehicle owners have different desires regarding the continued use of the OEM Filter Housing. Keeping the OEM...
- Page 6 Step 2: Disconnect the Vehicle's Battery (or batteries, as diesel trucks typically have more than one) by disconnecting the Negative or Ground Terminal(s) of each Battery to disable the Vehicle's Electrical System. Step 3: Loosely attach the System Bracket (item S2) and bushings (items S7) to the Front Rail Bracket (item S3), using the four (4) Captive Studs (items S6), Stud Washers (items S8) and Acorn Nuts (items S9).
- Page 7 Step 5: Loosen the hose clamps on the filler tube and the over flow tube to the fuel tank, located on the inside of the fender well. Then loosen the 2 bolts that secure the tank strap until only a few threads are holding it up. Once you have lowered the tank slightly, you must remove the electrical connector and the feed and return fuel lines on top of the tank.
- Page 8 Due to variations of depth between various fuel tanks, the draw tube included in this kit (item 14) will have to be cut to the correct length. If too much length is cut from the draw tube, then the vehicle will prematurely “run out of fuel” while significant fuel still remains in tank.
- Page 9 Install the modified fuel tank module (example shown to the right). Take extra care to ensure that the fuel tank level sender arm and sensor do not get damaged upon installation. Before seating the fuel tank module, ensure that the gasket seal is in its proper position prior to setting it in place.
- Page 10 VOLTMETER Topic: Finding proper Fuse Position, Socket Power Side and Fuse Tap Orientation FUSE BOX (APPEARANCE MAY VARY) This kit uses a Fuse Tap Assembly in the wiring harness, to allow a power tap from the Under-Hood Fuse Box to power the Lift Pump / Filtration System.
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Page 11: Double Check
Step 8: Secure the wiring harness (item 13) in the engine bay. DO NOT make the final connection of the power lines at this time. This will be your last step before starting the vehicle. Run the wiring harness (item 13) along the driver side frame rail and secure with Cable Ties (items 11). Connect the supplied wiring harness (item 13) to the Lift Pump / Filtration System as described. - Page 12 Below is a photo of the Lift Pump / Filtration with the Inlet Straining Filter (item 12) installed, use supplied Clamps (items 9) to secure hose to Straining Filter. The Straining filter is required to prevent foreign particles in the fuel from jamming the Lift Pump.
- Page 13 At the higher pump speed, the Fuelab Vortex Manifold may not regulate the fuel pressure ® adequately, requiring an external bypass style regulator such as the Fuelab Model 50102 Adjustable Bypass ® Regulator (unless a speed control scheme is used). Additional modification of the OEM fuel tank and additional wiring requirements (including aftermarket electrical relay) is REQUIRED for this mode of operation.
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Page 14: Limited Lifetime Warranty
How Do You Get Service? If something goes wrong with your Product, contact FUELAB at 618-344-3300, or send an e-mail with proof of purchase to: info@fuelab.com for a Return Authorization Number (RMA). After receiving your RMA send the product postage...
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