1. Introduction
The FASS RK-02 Relocation Kit is designed to reposition your DRP DRP02 fuel pump closer to the vehicle's fuel tank. This strategic placement reduces the distance the lift pump must pull fuel under vacuum, allowing it to push fuel under pressure to your Cummins engine more efficiently. This configuration helps extend the lifespan of the fuel pump, as pumps operate more effectively when pushing fuel rather than pulling it over long distances.
2. Safety Information
- Always disconnect the vehicle's battery before beginning any installation or maintenance.
- Ensure the vehicle is on a stable, level surface and properly supported with jack stands.
- Wear appropriate personal protective equipment, including safety glasses and gloves.
- Fuel is highly flammable. Work in a well-ventilated area away from open flames or sparks.
- Refer to your vehicle's service manual for specific procedures related to fuel system components.
3. Package Contents
Verify that all components listed below are present in your FASS RK-02 Relocation Kit before beginning installation.
Image Description: This image displays all components included in the FASS RK-02 Relocation Kit. Visible items include a coiled black wiring harness, a black L-shaped mounting bracket with three self-tapping screws, four small hose clamps, a long coiled blue fuel line, a small inline fuel filter, and various metal fuel fittings (straight and angled).
- Wiring Harness
- Fuel Line (Blue)
- Mounting Bracket
- Self-Tapping Screws (for bracket)
- Hose Clamps
- Inline Fuel Filter
- Various Fuel Fittings
4. Installation Instructions
4.1. Preparation
- Park the vehicle on a level surface and engage the parking brake.
- Disconnect the negative terminal of the vehicle's battery.
- Relieve fuel system pressure according to your vehicle's service manual.
- Gather all necessary tools, including wrenches, screwdrivers, and a drill.
4.2. Relocation Kit Installation
- Locate Mounting Position: Identify a suitable location on the vehicle's frame rail, closer to the fuel tank, for mounting the DRP DRP02 fuel pump. Ensure there is adequate clearance and that the location will not interfere with moving parts or be exposed to excessive road debris.
- Install Mounting Bracket: Secure the provided mounting bracket to the chosen frame rail location using the self-tapping screws. Ensure the bracket is firmly attached and stable.
- Mount Fuel Pump: Attach your DRP DRP02 fuel pump to the newly installed mounting bracket. Follow the pump manufacturer's instructions for secure attachment.
- Route Fuel Line: Carefully route the blue fuel line from the fuel tank to the inlet of the relocated fuel pump, and from the pump's outlet to the engine's fuel system. Avoid kinks, sharp bends, and areas where the line could be chafed or damaged. Use the provided hose clamps to secure connections.
- Install Inline Fuel Filter: Integrate the inline fuel filter into the fuel line as specified by the pump or vehicle manufacturer, typically between the fuel tank and the pump inlet. Ensure the flow direction is correct.
- Connect Wiring Harness: Connect the new wiring harness to the relocated fuel pump and integrate it into the vehicle's electrical system as per the pump's wiring diagram. Ensure all electrical connections are secure and protected from moisture and abrasion.
- Secure Lines and Wires: Use zip ties or other appropriate fasteners to secure all fuel lines and wiring harnesses, preventing them from hanging loose or contacting hot or moving components.
- Final Checks: Double-check all connections for tightness and proper routing. Ensure no fuel leaks are present.
- Reconnect Battery: Reconnect the negative terminal of the vehicle's battery.
- Test System: Turn the ignition to the 'ON' position (without starting the engine) to allow the fuel pump to prime. Check for any fuel leaks. Start the engine and monitor for proper operation and any unusual noises or warning lights.
5. Operation
Once installed, the FASS RK-02 Relocation Kit facilitates the optimal operation of your DRP DRP02 fuel pump by positioning it closer to the fuel tank. This allows the pump to operate more efficiently by pushing fuel under pressure, rather than pulling it over a longer distance. The system operates automatically with your vehicle's ignition, ensuring consistent fuel delivery to your Cummins engine.
6. Maintenance
- Regular Inspection: Periodically inspect all fuel lines, connections, and wiring for signs of wear, leaks, or damage.
- Filter Replacement: Replace the inline fuel filter according to the manufacturer's recommendations or if signs of clogging (e.g., reduced fuel flow, engine performance issues) are observed.
- Mounting Security: Check the mounting bracket and pump for secure attachment, especially after driving on rough terrain.
7. Troubleshooting
| Symptom | Possible Cause | Solution |
|---|---|---|
| Fuel Leakage | Loose connections, damaged fuel line, faulty fitting. | Tighten all connections. Inspect fuel lines and fittings for damage and replace if necessary. |
| No Fuel Pump Operation | Loose electrical connection, blown fuse, faulty wiring harness. | Check all wiring harness connections. Inspect vehicle fuses. Test for continuity in the wiring. |
| Reduced Engine Performance | Clogged fuel filter, air in fuel line. | Replace the inline fuel filter. Bleed air from the fuel system if applicable. |
| Unusual Noises from Pump | Air in fuel system, pump cavitation, loose mounting. | Ensure fuel tank is not low. Check for air leaks in the suction line. Verify pump is securely mounted. |
8. Specifications
| Feature | Detail |
|---|---|
| Brand | FASS |
| Model Number | RK-02 |
| Product Dimensions | Approximately 14 x 14 x 4 inches (packaging) |
| Item Weight | Approximately 2 pounds |
| Lift Type | Electric (for compatible pumps) |
| Compatibility | Designed for FASS DRP DRP02 pumps on Cummins engines |
9. Warranty and Support
For specific warranty information regarding your FASS RK-02 Relocation Kit, please refer to the documentation provided with your purchase or visit the official FASS website. For technical support, installation assistance, or to inquire about replacement parts, please contact FASS customer service directly. Keep your proof of purchase for warranty claims.
