Engine/Transmission (1998.5 - 2002) vulcan big line kit

[JMcrae]

Installed vulcan big line kit and moved to rail just in front of tank. Tucked above the transfer case skid plate.

Also just replaced lift pump . The other one was having intermittent psi issues. It would be running at 12 psi while cruising and then drop off to 7 psi and stay there untill I gave it some throttle and then it would go back to 12 psi . Then when back to cruising it would drop again.
It also would only go to 5 psi when bummping the starter. Pump was only 8 months old , local part store replaced it under warrenty.

Vulcan kit was a nice easy install and even with the old pump when it was running at only 7 psi when I was wot it only would go down to 6 with the big line kit
.
I will udate new pressures with new pump when I take it for a run.
Attached pictures of completed install

 

[olebum]

Thanks for posting the pictures: I received my Vulcan kit yesterday and am looking over all of the various compoments of the kit. What was the toughest task that you ran up against in the install? I am not completely mechanically challenged but have not done a lot of it. I am considering taking my truck to a diesel shop to have the installed done. Do you feel that a person with limited tools and experience could complete the job? Also, after the insall is complete is there a need to bleed the entire system to get the truck to run. Also, is there a lot of fuel spilled while doing the job.



Thank you for you help!

 

[Jefff929]

IMO you will want to bleed the system after install. It really is not that big a deal. Use a 19mm and loosen a turn or two, the lines to the three injectors you can get to on the drivers side of the valve cover. I think they are 1,4, & 5, it has been a while since I looked. Crank it over if it starts fine, if it dies start it again. When it fires up tighten the lines you cracked to quit the leaking. shut it off and wipe up the excess fuel.



Don't let bleeding the system stop you from getting this done. Oo.



IMO contact somebody in your area who has done it, and have a mini "Bomb" party.

 

[wtfd6]

i am about to order a kit myself. i have been wanting one for a while. especially now that i have a tst box installed. not hard to pull 13psi at idle down to 4psi wot. i have definately heard good things about this kit.


mark

 

[JMcrae]

The toughest part of the install was getting the 1/2 inch hose to slide over the one fitting that you had to put on after you figure out the length to cut the hose( The one from the fuel filter inlet to the outlet on the lift pump). Probably would have been easier if I took the hose off after cutting too length and heating the hose with hot air gun or hot water.

Putting the fitting on the vp44 wasn't that hard but just not lots of working space. Just be careful not to overtighten the fittings.

I only had 1/2 tank of fuel but I pinched of the rubber hose just before the factory hard line to stop any fuel loss. Maybe only lost about a cup of fuel, mostly what was in the lift pump itself.

I didn't drain the fuel filter ,I just took off the pre test port bolt to break the vacuum in the filter and opened the water drain for a second . Put test port bolt back on and closed drain. So the filter was still almost full.
I don't know if that was necessary, I thought if I didn't do that the fuel might siphon back out from the engine side and cause a need to bleed the whole system.
After the install all I did was bump the starter 5 times and it fired up without a burp, didn't have to bleed the system.

The tools I used were Wrenches- 7/16 for the bolts on the lift pump , 17mm for banjo bolts, 13/16 and 7/8, for the new fittings . Used 11mm socket for FF test bolt can't recall the size of socket for the factory fuel line bracket. Small pipe cutter to cut factory hard line. And vice grips to lightly pinch off rubber fuel line at tank.
I also took a small piece 1/2 inch line that was left over from the install and split it down one side and put it over the rubber line that was rubbing on the rail .

I am not that mechanically inclined ,but found this to be an easy install. The instructions from Eric at Vulcan are awesome . Took me about 2 hours to do .

 

[olebum]

Thanks JMcrea for the reply and you have just given me the confidence to tackle the job. I will let you know how it turns out.



You live in a beautiful city.

:-{}

 

[Bob Cochran]

I had less than half a tank of fuel but jacked front of truck up. No vise grips and minimum fuel loss. I removed he fuel fliter housing just because it made it a little easier besides needed to put in a new filter anyways. After install bumped stater several times and the last time cracked the connection at the VP on line from filter so it pushed any air and fuel out still minimum loss of fuel(lost more here than out of the tank). Started right up. Was easy. I think hardest part for me was moving around the line from fuel fliter to VP so it was not right over top of the power steering pump cap.

 

[Nate]

For the push lock connectors (ones that have the yellow ring) just spray the inside of the hose with WD-40 and it will make it alot easier to slip it on.



Where does the line tie into the tank? You have to reach up on the top of the tank and hook it up there??

 

[JMcrae]

I tied into the tank where the hard line meets the rubber line to the tank. Still down by the rail. located just infront of bottom side of tank

 

[Nate]

And the hard line there is 1/2"? I took a look on mine yesterday and it's only 3/8"

 

[JMcrae]

the line to the inlet of the lift pump supplied in the kit is 3/8 id I believe . It slides over the hard line and a clamp ,which is also supplied, holds it on. From the outlet to ff and vp is 1/2 inch.

 

[02cummins]

I ordered mine today, it is easy when you pay through paypal. can't wait to put it on, it looks relatively easy. thanks for the pics.