Katerina Swanson
Installing a diesel fuel tank sump kit can be a quick and easy process, with some kits claiming to cut installation time down to just a few minutes. The process typically involves drilling a hole into the fuel tank, slipping the clamp inside, and bolting the sump up to the clamp. Some kits, such as the FASS Fuel Sump Kit, feature a single-bolt design, requiring only one hole in the tank for easy installation. The G&R Performance Diesel Bottom Sump with Integrated Fuel Return System also promises a quick installation process by eliminating the need to run the return line of the fuel pump to the top of the fuel tank. Other kits, such as the SPELAB Aluminum Alloy Fuel Tank Sump Kit, offer similar benefits with integrated return systems and easy installation.
| Characteristics | Values |
|---|---|
| Installation | Drilling a hole into the fuel tank, slipping the clamp inside, and bolting the sump up to the clamp |
| Tools Required | Power drill, Allen wrench |
| Time | A few minutes to a couple of hours |
| Features | Single-bolt design, dual ports, large reservoir, quick-connect plug, return stand tube |
| Benefits | Eliminates common issues, enhances vehicle performance, prevents fuel problems, improves fuel delivery, maximises fuel usage, anti-oxidisation, corrosion-resistant |
| Compatibility | Airdog, FASS, Duramax Powerstroke, Cummins Diesel, Ford Powerstroke Diesel |
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What You'll Learn
Choosing the right sump kit
Compatibility
Ensure that the sump kit is compatible with your diesel fuel tank and vehicle. Some sump kits are specifically designed for certain vehicle models, such as Cummins, Duramax, or Powerstroke, while others are universal and can be used with a range of vehicles. Check the product specifications to confirm compatibility.
Installation Process
Look for a sump kit with an installation process that aligns with your skills and resources. Some kits require drilling only a single hole, while others may involve more complex modifications. Consider your comfort level with drilling and cutting, and choose a kit that matches your capabilities.
Features
Sump kits can offer various features that enhance their functionality. For example, some kits include a built-in return port, allowing for easy routing of return fuel back to the tank without modifying other components. Others may have a stand pipe that places returned fuel above the fuel feed, ensuring optimal fuel quality by eliminating the possibility of feeding aerated return fuel to your engine.
Quality and Reviews
Pay close attention to the quality of the sump kit and the reviews from other customers. Look for kits made with high-quality materials, such as corrosion-resistant components, and consider the overall durability and longevity of the product. Reading customer reviews can provide valuable insights into the performance, ease of installation, and potential issues or benefits of a particular sump kit.
Customization
Depending on your specific needs, consider a sump kit that offers customization options. For example, some kits allow for the customization of aftermarket fuel systems, maximizing fuel delivery and providing flexibility in installation.
By carefully considering these factors, you can choose the right sump kit for your diesel fuel tank, ensuring a seamless installation process and optimal performance for your vehicle.
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Drilling the hole
First, identify the lowest point of the fuel tank. This is typically found below the fuel tank module, and you can use the dimple as a centre point reference if available. Mark this point as the centre for your hole. It is important to ensure that you have selected the lowest point to facilitate unrestricted fuel flow to the sump system.
Next, you will need to drill a pilot hole at the marked centre point. This initial hole will allow the fuel to drain out of the tank. Make sure to use the appropriate size drill bit for the pilot hole to ensure accuracy.
After drilling the pilot hole, you can move on to creating the main hole. For this step, you will need a hole saw. The size of the hole saw will depend on the specific sump kit you are installing. Refer to your sump kit instructions to determine the correct hole size. For example, the FASS Fuel Sump Kit requires a 3 and 3/4-inch hole saw. Place the hole saw at the centre point and drill carefully to create the main hole.
Once the main hole is drilled, you will need to debur the hole and remove any plastic shavings or debris created during the drilling process. This step ensures that the area is clean and smooth before installing the sump.
Finally, inspect the drilled hole to ensure it is the correct size and free from any burrs or imperfections. This is an important step to ensure a proper seal and prevent potential leaks. Once you are satisfied with the hole, you can proceed to the next step of installing the sump kit, which may include inserting the sump ring or clamp and bolting the sump in place.
Remember to follow all safety precautions when drilling into your fuel tank and refer to the specific instructions provided with your diesel fuel tank sump kit for additional guidance.
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Securing the sump
Similarly, the G&R Performance Diesel sump kit features a "clamp-in O-ring style seal" instead of the standard bolts used in other kits. This design makes installation quicker and easier. The sump is bolted to the clamp, which is slipped inside the fuel tank, ensuring a secure fit.
The SPELAB Aluminum Alloy Fuel Tank Sump Kit also has an O-ring seal, with a single-bolt design for simple installation. This kit includes a 3" hole saw, which is used to create an installation hole in the fuel tank. The inner ring of the sump is then inserted through this hole.
When installing a bottom sump with an AirDog or Fass Pump, an additional step may be required to cap off any open fuel supply or return lines. This can be done using an aluminum plug to prevent fuel leaks and keep dirt out of the fuel tank.
Overall, the process of securing the sump varies slightly depending on the kit, but the common goal is to create a tight seal using O-rings, washers, clamps, or bolts. This ensures the sump is securely attached to the fuel tank and prevents any fuel leaks.
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Attaching the sump bowl
Prepare the Sump Bowl and the Fuel Tank:
Begin by gathering the necessary components, including the sump bowl, O-ring seal, clamp, and fittings. Inspect the fuel tank to identify the lowest point, which is the ideal location for installing the sump bowl. Clean the area around the chosen spot, ensuring it is free of debris, grime, or any residue.
Drill the Hole:
Using a power drill, carefully drill a hole at the marked location. The hole size may vary depending on the sump kit, but typically, a 2 1/4 inch hole is standard and considered the smallest on the market. This hole will accommodate the sump bowl and the necessary fittings.
Insert the Clamp:
After drilling the hole, insert the clamp into the fuel tank through the drilled hole. Ensure the clamp is securely positioned and ready for the next step.
Attach the Sump Bowl:
Slide the sump bowl into the clamp. Ensure the sump bowl is securely attached to the clamp and seated properly. The sump bowl should have an O-ring seal, creating a tight and leak-proof connection between the bowl and the fuel tank.
Secure with Bolts:
Use the provided bolts and brass washers to securely fasten the sump bowl to the clamp and the fuel tank. Tighten the bolts firmly, but be careful not to overtighten, as this may damage the O-ring seal or the fuel tank itself.
Connect the Hoses:
Finally, attach the hoses to the sump bowl using the provided fittings. Ensure all connections are secure and leak-free. Depending on your specific sump kit, you may need to connect the return line of the fuel pump to the sump bowl as well.
It is important to follow the specific instructions provided with your diesel fuel tank sump kit, as different kits may have slight variations in the installation process. Always take your time and work carefully to ensure a proper installation that will provide reliable performance and prevent fuel leaks.
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Connecting the lines
Once the sump is in place, you can begin connecting the lines. The FASS Fuel Sump Kit, for example, comes with clear instructions on how to determine the appropriate fittings based on your suction line size. It's important to refer to the installation instructions to ensure you're using the correct fittings.
The next step is to attach the suction and return lines to the sump. This process will vary depending on the specific sump kit you're using, but it typically involves threading the lines through the appropriate ports and securing them in place. It's important to ensure that all connections are tight and secure to prevent leaks.
Some sump kits, like the G&R Performance Diesel Bottom Sump with Integrated Fuel Return, eliminate the need to run the return line of your aftermarket fuel pump to the top of the fuel tank, simplifying the installation process. This particular kit features a unique clamp-in O-ring style seal that speeds up the installation process and provides a secure seal.
After connecting the lines, it's important to test the system for leaks. Add a small amount of fuel to the tank and carefully check all connections for any signs of leakage. If you encounter any issues or have questions, it's always best to consult a professional or the customer service team of the sump kit manufacturer.
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Frequently asked questions
A diesel fuel tank sump kit is a device that is installed in a diesel fuel tank to improve the flow of fuel and prevent leaks. It typically includes a sump ring, a return stand tube, and a fuel pump.
To install a diesel fuel tank sump kit, you will need to drill a hole in the fuel tank, insert the sump, and secure it with an O-ring and washer. You will also need to attach the sump bowl and connect the suction and return lines. Refer to the kit's instructions for specific details.
Diesel fuel tank sump kits offer several benefits, including improved fuel flow, the ability to use every last drop of fuel in the tank, and reduced sediment in the fuel filter system. They can also eliminate the need to run the return line of the fuel pump to the top of the fuel tank, simplifying the installation process.
It is important to follow the installation instructions carefully to avoid leaks or other issues. Some users have reported unclear instructions with certain kits, so it may be helpful to seek guidance from a professional or the manufacturer's customer support if needed.
