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Cleaner Diesel: Fuelab Lift Pump and DRP Fuel Sump

Today’s diesel engines are using some of the most sophisticated, extreme high-pressure fuel systems in the automotive industry. CP3, CP4 and injector technology is advancing at an ever-quickening pace. These technological advancements come at a price and higher levels of protection are needed to keep these parts safe and working at maximum capacity.

Whether you’re driving a brand new 2014-2015 model year truck or competing in an older model with aftermarket parts like modified pumps and injectors, keeping a constant flow of clean diesel fuel is vital to your truck’s longevity and performance. The new common-rail injection systems use extremely tight tolerances to inject fuel into the combustion chamber at pressures nearing 30,000 psi. Because of this design, even the smallest particle or debris in the fuel system can create a restriction, plug up ports, or even scar and harm the internals of a pump or injector.

Obviously, knowing this, the OEM manufacturers aren’t going to turn their heads at good filtration and their engineers have spent countless hours ensuring that fuel can be filtered properly and any water can be separated before entering the injection pump. This doesn’t mean, however, that there isn’t room for improvement. In most applications, whether it be an all-stock truck or a heavily modified competition vehicle, the right high-performance lift pump system like the new Velocity from Fuelab can not only further filter that fuel and remove any entrapped air in the system, but it can also aid in performance by feeding a larger volume of fuel to the engine for better fuel rail pressure and a more efficient burn in the combustion chamber.

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1. The Fuelab Velocity 200-GPH fuel system uses a lightweight high-flow brushless DC motor to ensure long pump life. The “wet motor” design means there are no seals to wear out. The unit also has internal speed control with a pulse width modulated signal. This means volume and pressure can be set to precisely what each application requires. Complete installation kits designed specifically for Cummins, Duramax and Power Stroke applications with model-specific fittings and wiring harnesses are available.
1. The Fuelab Velocity 200-GPH fuel system uses a lightweight high-flow brushless DC motor to ensure long pump life. The “wet motor” design means there are no seals to wear out. The unit also has internal speed control with a pulse width modulated signal. This means volume and pressure can be set to precisely what each application requires. Complete installation kits designed specifically for Cummins, Duramax, and Power Stroke applications with model-specific fittings and wiring harnesses are available.
2. On the 2001-2010 GM Duramax application, seen here, the Velocity pump installation will take an average of three to four hours to complete. Some fuel system tools are required that may not be in your toolbox, most specifically a fuel line disconnect tool. The first step to the basic install of the kit involves removing the fuel tank for installation of the supplied pick-up tube. Since we’ll be replacing it with a full billet fuel sump kit from Deviant Race Parts (DRP), this fuel tank will not be dropped from the vehicle. However, the factory fill tube needs to be removed and spliced with the new return line from the Fuelab pump.
2. On the 2001-2010 GM Duramax application, seen here, the Velocity pump installation will take an average of three to four hours to complete. Some fuel system tools are required that may not be in your toolbox, most specifically a fuel line disconnect tool. The first step to the basic install of the kit involves removing the fuel tank for installation of the supplied pick-up tube. Since we’ll be replacing it with a full billet fuel sump kit from Deviant Race Parts (DRP), this fuel tank will not be dropped from the vehicle. However, the factory fill tube needs to be removed and spliced with the new return line from the Fuelab pump.

Fuelab Velocity offers diesel-specific 100-GPH and 200-GPH lift pumps and filtration kits. The Velocity kits represent a major step forward in efficiency and technology for the light duty diesel market. As a company that’s been leading the automotive fuel delivery market for years, it seemed only natural that Fuelab would jump into the diesel scene and offer their same great products to the Cummins, Duramax and Power Stroke crowds. Using a speed-controllable DC brushless motor, the Velocity lift pump kit offers excellent durability with stated higher flow rates and lower current draws than their brushed motor-equipped competitors. On the 200-GPH units, the unique air separation cylinder, known as the Fuelab Vortex, offers superior air removal, which will quiet engine operation and help to extend the life of the injection pump and injectors.

3. Fuelab’s unique frame mount bracket comes pre-drilled with multiple holes to allow complete adjustability of the pump’s vertical mounting position under the truck. The included studs can be installed in your selected holes and small rubber bushings will work as isolators to help limit vibration and noise from the lift pump kit being transmitted into the chassis.
3. Fuelab’s unique frame mount bracket comes pre-drilled with multiple holes to allow complete adjustability of the pump’s vertical mounting position under the truck. The included studs can be installed in your selected holes and small rubber bushings will work as isolators to help limit vibration and noise from the lift pump kit being transmitted into the chassis.
4. Using a rather large fuel filter with a built-in water separation feature, the Velocity system mounts to the supplied bracket. This was mounted inside the driver-side frame rail. The long cylindrical shape to the right of the filter is Fuelab’s unique Vortex air separation chamber that helps to remove any entrapped air from the fuel before it enters the pump that feeds it onto your CP3 and high-pressure injection system. By removing air from the system and better filtering the fuel, you can expect longer life from your injection pump and injectors, as well as reduced engine noise.
4. Using a rather large fuel filter with a built-in water separation feature, the Velocity system mounts to the supplied bracket. This was mounted inside the driver-side frame rail. The long cylindrical shape to the right of the filter is Fuelab’s unique Vortex air separation chamber that helps to remove any entrapped air from the fuel before it enters the pump that feeds it onto your CP3 and high-pressure injection system. By removing air from the system and better filtering the fuel, you can expect longer life from your injection pump and injectors, as well as reduced engine noise.

Installation kits are offered for each truck, with vehicle-specific lines, fittings and wiring harnesses to aid in the installation process. The design of the pump and its mounting hardware offer extremely quiet operation, without hindering its fuel output. The pumps are internally controlled for speed and output. However, the system can also be pulse width modulated with an external signal to match pump output with engine demand for competition-style vehicles. This setup has no adverse affect on reliability for day-to-day driving. All systems come preset at 8-psi but can be easily adjusted depending on your application. Additionally, the Velocity system is backed by a two-year limited warranty and is fully inspected and tested before leaving the Fuelab shop in Litchfield, Illinois.

A complementary fuel system upgrade is the Deviant Race Parts (DRP) billet fuel sump kit. While the Fuelab Velocity installation kit includes the required high-flow pick-up tube to install in the fuel tank, removing the tank from the vehicle can be somewhat labor intensive and time consuming. In addition, if this new tube isn’t installed properly or cut to the correct length, you could leave fuel on the floor of the tank that won’t be available to you.

To resolve some of these issues and maintain the maximum flow of fuel to a lift pump, Deviant Race Parts of Coeur D’Alene, Idaho, offers its fuel sump kit. The latest unit is an all-new design that’s easier to install than ever. DRP’s new design makes installation simple, and only requires cutting one hole on the bottom side of the tank. Fewer holes mean fewer chances of leaking, right?

5. On the crew cab GM truck seen here, the Velocity kit fits directly in front of the fuel tank under the back driver-side door. On the Fuelab no-drill bracket, the pump can be mounted high enough that the base of the filter is barely visible from the side of the vehicle. Keeping it tucked up nice and close also helps keep it clear of road debris and keep the soon to be added fuel hoses routed cleanly inside the frame.
5. On the crew cab GM truck seen here, the Velocity kit fits directly in front of the fuel tank under the back driver-side door. On the Fuelab no-drill bracket, the pump can be mounted high enough that the base of the filter is barely visible from the side of the vehicle. Keeping it tucked up nice and close also helps keep it clear of road debris and keep the soon to be added fuel hoses routed cleanly inside the frame.
6. To help protect the pump from foreign objects, Fuelab includes an inline filter that needs to be installed in the new feed line that runs from the pick-up tube to the inlet of the pump. Again, on this application, the feed line is going to be pulling fuel from the DRP sump that will be installed on the bottom side of the fuel tank.
6. To help protect the pump from foreign objects, Fuelab includes an inline filter that needs to be installed in the new feed line that runs from the pick-up tube to the inlet of the pump. Again, on this application, the feed line is going to be pulling fuel from the DRP sump that will be installed on the bottom side of the fuel tank.
7. The Fuelab Prodigy pump provides more fuel than what can be used by the engine. The system is designed so any unused fuel and air that are separated inside the Fuelab Vortex is sent through a small hose back to the truck’s fuel fill neck. The Duramax installation kit included a powder-coated steel pipe insert that’s spliced in line with the fill neck hose to ensure a leak-free installation.
7. The Fuelab Prodigy pump provides more fuel than what can be used by the engine. The system is designed so any unused fuel and air that are separated inside the Fuelab Vortex is sent through a small hose back to the truck’s fuel fill neck. The Duramax installation kit included a powder-coated steel pipe insert that’s spliced in line with the fill neck hose to ensure a leak-free installation.
8. Fuelab’s pump was designed with diesel fuel in mind, to ensure longevity and performance, whether it’s being installed in a daily driver or an all-out competition vehicle. The Prodigy pump features a quiet brushless motor that offers continuous duty motor speed that can be adjusted on demand. The pump can also be pulse width modulated to keep up with higher demands based off an outside signal or input.
8. Fuelab’s pump was designed with diesel fuel in mind, to ensure longevity and performance, whether it’s being installed in a daily driver or an all-out competition vehicle. The Prodigy pump features a quiet brushless motor that offers continuous duty motor speed that can be adjusted on demand. The pump can also be pulse width modulated to keep up with higher demands based off an outside signal or input.
9. Once the Fuelab system is fully installed, the DRP fuel sump kit needs to be mounted in the factory fuel tank, so the pump’s feed line can be connected and start pulling fuel from the tank to feed that hungry Duramax. While it may seem a bit crazy to drill a hole in the bottom of your fuel tank, the DRP sump design will ensure a leak-free seal.
9. Once the Fuelab system is fully installed, the DRP fuel sump kit needs to be mounted in the factory fuel tank, so the pump’s feed line can be connected and start pulling fuel from the tank to feed that hungry Duramax. While it may seem a bit crazy to drill a hole in the bottom of your fuel tank, the DRP sump design will ensure a leak-free seal.

The new sump comes with a square O-ring, or gasket, with a larger surface area than competing sump kits. This ensures a leak-free seal. With just one hole to drill and two bolts to tighten, the new DRP sump install can be done in just 20 to 30 minutes, versus two to four hours for other kits. The other advantage to an in-tank sump system is the lift pump, which when mounted below the tank, will benefit from gravity to feed fuel to the pump. This reduces load on the lift pump, as it isn’t trying to pull fuel up and out of the tank.

Together, the Fuelab Velocity 200-GPH lift pump system and DRP fuel sump should be able to supply all the clean fuel your diesel engine could ever need. Rated to support more than 750 hp, the systems can be used on everything from your mildly modified daily driven tow rig to an all-out track star, whether it’s on the asphalt or the dirt. DW

10. Obviously, this is a job you’ll want to tackle with an empty tank of fuel, but since it’s nearly impossible to get out every last drop, once the pilot hole is drilled, be prepared to catch the little fuel that drains out. There’s no turning back now.
10. Obviously, this is a job you’ll want to tackle with an empty tank of fuel, but since it’s nearly impossible to get out every last drop, once the pilot hole is drilled, be prepared to catch the little fuel that drains out. There’s no turning back now.
11. Once the fuel has drained, a 3 ¼-in. hole saw finishes off the job you’ve started with a pilot bit. With the large section of tank drilled out, you can simply reach inside with your hand to remove any shaving or debris on the bottom side of the tank to be sure you have a clean, flush surface for the DRP sump kit to mate up to. Remove any burrs before proceeding.
11. Once the fuel has drained, a 3 ¼-in. hole saw finishes off the job you’ve started with a pilot bit. With the large section of tank drilled out, you can simply reach inside with your hand to remove any shaving or debris on the bottom side of the tank to be sure you have a clean, flush surface for the DRP sump kit to mate up to. Remove any burrs before proceeding.
12. The DRP kit comes with a metal in-tank bracket that’s slid inside the fuel tank with the beveled side facing up. The sump is bolted to this mounting bracket for a tight, leak-free seal.
12. The DRP kit comes with a metal in-tank bracket that’s slid inside the fuel tank with the beveled side facing up. The sump is bolted to this mounting bracket for a tight, leak-free seal.
13. Next, install the two supplied bolts through the bottom side of the fuel sump and thread them into the previously installed in-tank bracket. These bolts will then need to be torqued to 13 ft.-lb. These torque specs are crucial to a leak-free and lasting seal.
13. Next, install the two supplied bolts through the bottom side of the fuel sump and thread them into the previously installed in-tank bracket. These bolts will then need to be torqued to 13 ft.-lb. These torque specs are crucial to a leak-free and lasting seal.
14. The fuel hose can be slid onto the barbed fitting of the fuel sump and the tank can be refilled with fuel. The new DRP sump should offer quieter lift pump performance, along with reduced wear on the pump since it won’t have to fight as hard to pull fuel from the tank, as gravity can now aid in feeding the lift pump. Plus, there are no more worries of ¼-tank troubles and sucking air. Just know that with a sump, once the motor stops from a low fuel condition, you’re not low… you’re out. This is a downside for some, so if you want to keep your original fuel reserve, take the extra time and install the Fuelab in-tank pick-up.
14. The fuel hose can be slid onto the barbed fitting of the fuel sump and the tank can be refilled with fuel. The new DRP sump should offer quieter lift pump performance, along with reduced wear on the pump since it won’t have to fight as hard to pull fuel from the tank, as gravity can now aid in feeding the lift pump. Plus, there are no more worries of ¼-tank troubles and sucking air. Just know that with a sump, once the motor stops from a low fuel condition, you’re not low… you’re out. This is a downside for some, so if you want to keep your original fuel reserve, take the extra time and install the Fuelab in-tank pick-up.
SOURCES:

Fuelab

217.324.3737

Fuelab.com

Deviant Race Parts (DRP)

208.292.4401

DeviantRaceParts.com

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