SUCTION TUBE KIT

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					Installation Manual
STK-1001




                      SUCTION TUBE KIT
                          Pickup Truck Applications:

                Dodge Cummins:               1994 - 2006
                Ford Powerstroke:            1999 – 2006
                GM Duramax:                  2001 - 2006
Refer to pages 3 and 4 when installing on Dodge and Ford pickup truck applications and pages
5 and 6 when installing on GM pickup truck applications.


                                        Contents Include:

         Description                         Quantity        Part #




1.    3/8” x 1/2” (mpt x flared 90°)   --         1     --   --       --




2.    Bulkhead (3/8 x 3/8) --     --   --         1     --   BHF-1001




3.    Bulkhead Grommet --         --   --         1     --   RS2770




4.    3/8 mpt Suction Tube        --   --         1     --   ST-1001




5.    3/8” x ½” (push lock x female flare)        1     --   PL-1002




6.    ½” x   ½” (push lock x female flare)        1     --   PL-1005




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Installation Manual                                                                        STK-1001
Suction Tube Kit



Removing & Preparing Fuel Tank:                 Use the following photo’s to complete this installation.

Some of the photo’s are of a different application, procedures are the same.




        Photo 1                                                           Photo 2




        Photo 3                                                           Photo 4




        Photo 5                                                          Photo 6

        1.      Remove the filler neck tube from the truck by loosening the clamps at both ends.

        2.      Disconnect overflow tube from the fuel tank.

        3.      Disconnect the factory suction and return line. The factory lines are removed by
                pressing in on the two tabs located in the connecting harness. These tabs are
                opposite of each other (Dodge) or by using a 3/8” quick disconnect tool (Ford).



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Installation Manual                                                                         STK-1001
Suction Tube Kit




Removing & Preparing Fuel Tank: Continued

        4.      Disconnect the factory electrical harness located between the suction and return
                lines on top of the fuel tank.

        5.      With the fuel tank empty of fuel now remove it from the vehicle.

        6.      As seen in photo 1 remove the lock ring or nut on the top of the fuel tank.

        7.      Once the lock ring or nut is removed, remove pick up module from fuel tank.

        8.      Reviewing photo’s 2 and 3, place the lock ring or nut back into place for
                measurement reasons. Lay the grommet into proper location and use a punch to
                mark the center. Drill a 1 ¼” hole, catch all debris, example cup.

        9.      Using photo 4 assembly the pick up assembly. Use pipe tape on the pipe threads.

        10.     Insert the grommet into the 1 ¼” hole. Place the pick up assembly into grommet,
                take measurements so the bottom of the suction tube is only 1/8” (no more than 2
                quarters stacked) from the bottom of the fuel tank.

        11.     Before cutting the suction tube triple check the measurements, it is much more
                efficient to cut the tube to long and then correct to proper length than it would be to
                cut to short.

        12.     With proper length being obtained with the suction tube kit, debur and flush
                assembly. Place the assembly into the grommet as seen in photo 5.

        13.     Reinstall install pick up module.

        14.     Reinstall fuel tank. Remember to connect both factory fuel lines, wire harness and
                torque tank hanger bolts to proper specifications.

        15.     Insert the 3/8” x 1/2" (push lock x female flare) fitting into the fuel line. Oil the fitting
                and fuel line.

        16.     As seen in photo 6 attach the fitting discussed in the previous step. Torque              to
                proper specifications.




                                                                                                           4
Installation Manual                                                                       STK-1001
Suction Tube Kit


Removing & Preparing Fuel Tank:                 Use the following photo’s to complete this step.
Some of the photo’s are of a different application, procedures are the same.




             Photo 6                               Photo 7                          Photo 8




             Photo 9                                Photo 10                         Photo 11




              Photo12                               Photo 13


        1.      Secure vehicle from rolling.

        2.      Remove the drive shaft to gain access to the top of the fuel tank.

        3.      Remove the filler neck tube from the top of the fuel tank by loosening the clamp.

        4.      Disconnect overflow tube from the fuel tank.

        5.      Remove the 3 bolts holding the fuel cooler to the mounting bracket. The fuel cooler
                is located in front of the fuel tank.

        6.      Using a fuel line disconnect tool disconnect the factory suction & return located
                above the fuel cooler and connecting to the fuel cooler. Place the disconnect tool
                around the fuel tube and slide the tool under the fuel line connection to release the
                fuel line. Example: Photo 6.

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Installation Manual                                                                    STK-1001
Suction Tube Kit

Removing & Preparing Fuel Tank:            Continued

        7.       Disconnect the factory electrical harness located on top of the fuel tank.

        8.      With the fuel tank empty of fuel now remove it from the vehicle.

        9.      As seen in photo 7 remove the lock ring on the top of the fuel tank.

        10.     Once the lock ring is removed, remove pick up module from fuel tank. As seen in
                photo 8.

        11.     Reviewing photo’s 9 and 10, place the lock ring back into place for measurement
                reasons. Lay the grommet into proper location and use a punch to mark the
                center. Drill a 1 ¼” hole, catch all debris, example cup.

        12.     Using photo 11 assembly the pick up assembly. Use pipe tape on the pipe
                threads.

        13.     Insert the grommet into the 1 ¼” hole. Place the pick up assembly into grommet,
                take measurements so the bottom of the suction tube is only 1/8” (no more than 2
                quarters stacked) from the bottom of the fuel tank.

        14.     Before cutting the suction tube triple check the measurements, it is much more
                efficient to cut the tube to long and then correct to proper length than it would be to
                cut to short.

        15.     With proper length being obtained with the suction tube kit, debur and flush
                assembly. Place the assembly into the grommet as seen in photo 12.

        16.     Reinstall install pick up module.

        17.     Remove factory suction line from the fuel tank using a quick disconnect tool and
                cap this open port.

        18.     Insert the 1/2” x 1/2" (push lock x female flare) fitting into the fuel line. Remember
                to oil the fitting and fuel line.

        19.     As seen in photo 13 attach the fitting discussed in the previous step. Torque to
                proper specifications.

        20.     Reinstall fuel tank. Remember to connect, wire harness and torque tank hanger
                bolts to proper specifications.

        21.     Reconnect filler neck and overflow tube to the fuel tank and torque the clamp to
                proper specifications.

Revised:        11-28-06
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